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: Various embodiments of a gas burner igniter assembly are shown, described, and claimed herein. One embodiment of an igniter comprises an electrode at least partially encapsulated in an insulating body. The body of the igniter includes a sleeve portion and a hood portion, whereby the hood portion is disposed in close proximity to an outlet port of a gas burner. The body of the igniter, including the hood portion, is made from a non-conductive and heat and corrosion resistant material to withstand the harsh conditions to which it is subjected. The hood portion is configured to at least partially surround and cover a tip of the electrode, thereby facilitating an accumulation of a combustible gas/air mixture near the electrode. The sleeve portion is an elongated tubular member which is connected to a lead wire at a first end and the hood portion at the second end. The gas burner igniter assembly includes a bracket for holding the igniter in close proximity to the gas burner.

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 control valve for regulating the flow of gas to a burner tube for a barbecue grill, wherein the control valve includes multiple flow settings, including a sear setting. At the sear setting, the valve is capable of providing additional gas flow to the gas burner to provide the intense heat needed to sear food. At the remaining settings, the valve is capable of providing an appropriate amount of gas flow for conventional cooking of food. Another embodiment of the gas valve is adapted to reduce the rotational offset between the off position and the maximum flow position as compared to the valves of the prior art. In that embodiment, the angular offset between the off position and the maximum flow position is approximately 45°.

Abstract: The present invention provides a cooking grate for use within a barbecue grill assembly comprising a cooking chamber and a gas burner positioned in a lower portion of the cooking chamber. The grate has a plurality of elongated members defining a cooking surface and multiple openings. The grate further has a grease control assembly that is cooperatively positioned over a burner flame region to direct and control the flow of grease generated by cooking food on the grate. The grease control assembly has at least one rib group and at least one ledge. The rib group comprises a plurality of ribs, each rib having a first inclined surface and a second inclined surface. The grease control assembly also has an outer ridge and an inner ridge depending from a lower surface of the grate. With these structures, the grate prevents grease and byproducts from draining onto the burner flame region.

Abstract: The present invention provides a cooking grate for use within a barbecue grill assembly comprising a cooking chamber and a gas burner positioned in a lower portion of the cooking chamber. The grate has a plurality of elongated members defining a cooking surface and multiple openings. The grate further has a grease control assembly that is cooperatively positioned over a burner flame region to direct and control the flow of grease generated by cooking food on the grate. The grease control assembly has at least one rib group and at least one ledge. The rib group comprises a plurality of ribs, each rib having a first inclined surface and a second inclined surface. The grease control assembly also has an outer ridge and an inner ridge depending from a lower surface of the grate. With these structures, the grate prevents grease and byproducts from draining onto the burner flame region.

Abstract: The present invetnion provides a cooking grate for use within a barbecue grill assembly comprising a cooking chamber and a gas burner positioned in a lower portion of the cooking chamber. The grate has a plurality of elongated members defining a cooking surface and multiple openings. The grate further has a grease control assembly that is cooperatively positioned over a burner flame region to direct and control the flow of grease generated by cooking food on the grate. The grease control assembly has at least one rib group and at least one ledge. The rib group comprises a plurality of ribs, each rib having a first inclined surface and a second inclined surface. The grease control assembly also has an outer ridge and an inner ridge depending from a lower surface of the grate. With these structures, the grate prevents grease and byproducts from draining onto the burner flame region.

Abstract: The present invention provides a cooking grate for use within a barbecue grill assembly comprising a cooking chamber and a gas burner positioned in a lower portion of the cooking chamber. The grate has a plurality of elongated members defining a cooking surface and multiple openings. The grate further has a grease control assembly that is cooperatively positioned over a burner flame region to direct and control the flow of grease generated by cooking food on the grate. The grease control assembly has at least one rib group and at least one ledge. The rib group comprises a plurality of ribs, each rib having a first inclined surface and a second inclined surface. The grease control assembly also has an outer ridge and an inner ridge depending from a lower surface of the grate. With these structures, the grate prevents grease and byproducts from draining onto the burner flame region.