Assemblable fire pit and outdoor grill from concrete based artificiall stone
A modular outdoor barbeque grill and firepit is constructed of artificial stone-like slab members, which permit a uniform construction method by utilizing only a single block with a universal joint configuration to create an easily assembled, disassembled, re-assembled, and inexpensively manufactured product. Simple variation in the slab members' length, as well as relocation of the joint permits tremendous versatility of product design without increasing complexity of assembly. Slab members are cast of air-entrained concrete in elastomeric molds for reduced density and lighter weight members, which have advantageous thermal properties, exhibit greater longevity in adverse weath conditions, and may be so formed with pigments to resemble stone, brick, or decorative mosaic tile. The ease of construction by the design of this invention also permits quick transition between a backyard fire pit and a barbeque grill with a sophisticated appearance.
This application claims priority on Provisional U.S. Patent Application Ser. No. 61/128,531, filed May 22, 2008, the disclosures of which are incorporated by reference.
FIELD OF THE INVENTIONThe present invention relates to products made from artificial stone, and particularly to a modular firepit and outdoor grill constructed of artificial stone slab members, and more particularly, one which has a uniform construction method utilizing a single block to be easily assembled, disassembled, re-assembled, and inexpensively manufactured.
BACKGROUND OF THE INVENTIONStone firepits and barbeque grills are frequently found in outdoor locations where their durability and aesthetics permit containment of a fire for recreational purposes, such as for campers at campsites and parks, as well as public and private outdoor entertainment areas. Most of such firepits or grills are made from real stone and many are consolidated into a structural object by adhering the stone elements with the use of cement or concrete binder. Both the weight of such assembled firepits and grills and the complexity of the necessary assembly process do not lend them to be relocated either through disassembly or by transporting while fully assembled.
The ability to have a product which appears to be made of stone and has a configuration visually similar to a real stone fire/barbeque pit, but which can be easily assembled and disassembled has value for end users wishing the benefits of a stone fire/barbeque pit without having the limitations of non transportability.
Such an advantageous product has thus far been unavailable. One invention attempting to fulfill those needs is shown by U.S. Pat. No. 5,186,161 to Shumock. The Shumock invention is for a modular fireplace, and as described, it utilizes fire blocks with interlocking joints. While the modular nature of the Shumock invention permits transportability, the ease of relocation is severely hampered by the complexity of the various different joints utilized for the blocks, and by the multitude of various shaped and sized blocks required to construct the Shumock fireplace. In addition, there is no versatility in the end-product, in that only one unique fireplace configuration is attainable, and furthermore, it has limited adaptability to alternatively serve as an outdoor grill.
In order for such a modular fireplace to realistically be transportable, a simpler means of assembly needed to be created. The problems of the prior art are solved herein with novel design which permits assembly of a firepit or grill with only a single configuration of block.
SUMMARY OF THE INVENTIONA fire barbeque pit is assembled from a series of artificial stone slabs formed from concrete which has been surface pigmented with particles of a metal oxide to mimic the appearance of stone. The slabs have interlocking male and female grooves which allow for perpendicular inter-locking placement of the slabs. The indentations allow for the slabs to overlap at their extremities creating a stable structure which can be assembled and disassembled without the use of cement or binding concrete to consolidate the structure. This allows for easy on-site assembly, subsequent disassembly and transportation from the site after use.
In one preferred embodiment of the invention the slabs of the present invention have a body portion with top surface, bottom surface and a pair of side surfaces that extend from the top surface to the bottom surface. The slab formed by these surfaces has a generally rectangular or square cross section. The slab also has a first end portion and a second end opposite the first end. Each of the end portions is separated from the body portion by at least one recessed portion. The recessed portion is designed to mate with a recessed portion of a second slab that is positioned transverse to the first slab thereby to removably interlock to the slabs. In forming the barbecue of the present invention, there is a base slab where there are recesses on the top surface and there is a bottom surface that preferably extends from said first end to said second end without a recess portion. This will provide a flat surface for the barbecue to rest. Similarly, the top slab has a recess on the bottom surface with the top surface relatively flat or finished. The lengths of the slabs can vary depending on how large a barbecue grill is desired.
OBJECTS OF THE INVENTIONIt is an object of this invention to provide a modular fire pit which may be assembled and disassembled for relocation.
It is a further object of this invention to provide a modular barbeque grill which may be assembled and disassembled for relocation.
It is another object of this invention to provide an interlocking block design which permits construction utilizing a minimum number of different shaped and sized blocks to reduce complexity of the assembly process, disassembly, and re-assembly.
It is another object of this invention to provide a block which is constructed of a lightweight material.
It is another object of this invention to provide an aesthetically appealing block which may be adapted to resemble stone, brick, or decorative mosaic tile.
It is another object of this invention to provide a block construction from lightweight concrete.
It is another object of this invention to provide a block with a joint design that may be utilized on every block of the assembly.
It is another object of this invention to provide a design which permits easy adjustment of the height of the fire area.
It is another object of this invention to provide a design which permits easy adjustment of the height of the grilling area.
It is another object of this invention to provide a design which permits easy adjustment of the height of a block fume hood.
The design of the basic member of this invention provides for an easily assembled and disassembled fire pit or barbeque grill. The design also readily lends itself to adding additional features which may be marketed separately or as a more complete package.
A fully featured barbeque grill 10 is shown in the photograph of
There are many possible fire pit shapes that can be formed from the blocks of the current invention, such as, but not limited to, a fire pit whose footprint forms a V-shape, a C-shape, a U-shape, a rectangle, or other polygon shape, or even a curved shape. To be illustrative of such possibilities, a rectangular fire pit 13 is described.
The fire pit 13 shown in
A block may be formed, in a preferred embodiment, with concrete poured into elastomeric molds. The concrete generally will be allowed to set for 10-28 days and then be removed from the mold. The molds may be covered with one or more pigments to produce blocks, and ultimately a fire pit or grill, of a desired color or shade. The surface pigment may include, but is not limited to: particles of metal oxide; inorganic pigments; organic pigments; and organic dyes. The molds may also be constructed to achieve a finish on the concrete that mimics the appearance of stone, brick, or decorative mosaic tile. Different coatings are also available for concrete, for example, see U.S. Patent Ser. No. 12/069,734, filed on Feb. 12, 2008, the disclosures of which are herein incorporated by reference.
The blocks may also be formed using air entrained concrete. Air entrained concrete is advantageous for a number of reasons. It results in concrete products having a reduced density. The resulting products also have improved thermal properties. The resulting air entrained blocks provide greater insulation so that the block may be easily handled even when one side had been recently exposed to high heat. The air entrained concrete blocks also have greater resistance to degradation from freezing and thawing of trapped moisture which typically causes expansion and cracking of concrete.
The courses may be assembled to create a stable structure without the use of either mortar, or pins or fasteners of any kind, and unlike prior inventions, they are assembled by using only one joint configuration, which can be incorporated into the elastomeric mold. All of the blocks types, shown in
As previously stated, slab member 30 may incorporate a plurality of notches. The notches may comprise many different arrangments, including, but not limited to: a rectangular shaped notch 15; a V-shaped notch with matching V-shaped protrusion and indentation (see
A preferred embodiment of rectangular slab member 30 may are four notches 15: a first top notch 37 and a second top notch 38, both formed on upper surface 31; and a first bottom notch 39 and a second bottom notch 40, both formed on lower surface 32. The first top notch 37 on the upper surface 31 is located directly opposite the first bottom notch 39 on the lower surface 32, and the second top notch 38 on the upper surface 31 is located directly opposite the second bottom notch 40 on the lower surface 32, so as to form corresponding pairs of notches with one pair on each end of the slab member 30. One pair of notches 15 may be located near the front end surface 35, and the other corresponding pair of notches 15 may be located near the rear end surface 36. In the preferred embodiment, the corresponding pairs of notches are each located roughly the same distance away from end surfaces 35 and 36.
To construct a first course—the bottom course 20 for fire pit 13, a first pair of slab members 30 are positioned parallel to each other with the lower surface 32 of each pair flush with the ground, and spaced apart such that the distance between respective inside surfaces 33 or respective outside surfaces 34 is equal to the distance between first top notch 37 and second top notch 38. The reference to ground herein includes, but is not limited to, an assembly surface comprising soild, grass, a concrete slab, a brick or stone pedestal, etc. A second pair of slab members 30 are positioned parallel to each other and spaced apart so as to allow each of the first and second bottom notches 39 and 40 to dovetail with the first and second top notches 37 and 38 of the first pair of slab members. Successive courses 21 may then be added, with each such course having a primary pair of of slab members 30, and a secondary pair of slab members 30, which are assembled in like fashion to the first and second pairs of slab members 30, by dovetailing to the course immediately below, which may at first be the bottom course 20, and thereafter may be one of the successive courses 21.
Although a successive course 21 of slab members for fire pit 13, as with bottom course 41, will consist of four slab members 30, the fire pit height can also be adjusted by utilizing only one-half of a course, which may be accomplished through the addition of only two additional slab members 30. As illustrated in
The manufacturer will have the option of producing, and the user the option of purchasing, one additional block to tailor the fire pit 13, whereby that block—a plain slab member 80, does not have first and second top notches 37 and 38, but is otherwise formed exactly like slab member 30 having first bottom notch 39 and second bottom notch 40. Use of a pair of plain slab members 80 to add a half of a course permits the fire pit to have a smooth top edge as shown by fire pit 12 in
The fire pit 13 may also be converted for use as a barbeque grill by adding top grill 5 (
Additional dowel pins 9 could be inserted into another course so as to support a bottom grill 8. The bottom grill 8 could be formed similar to top grill 5, and also could alternatively incorporate a gas burner to supply heat for cooking, instead of using a fire.
To achieve a barbeque grill which is better adapted for cooking more comfortably and for servicing, a configuration may be easily created whereby the lower front portion of the grill may have a front opening 19 as seen in
Another feature which may be incorporated into an embodiment of the present invention is a backsplash as shown for barbeque grill 11, in
A further embodiment of the present invention may include a fume hood 3, one possible embodiment having a fume hood 3 is shown in
Another embodiment that incorporates a fume hood is shown in
The barbeque grill 10 would require two transition slab members 60, which are shown in
The versatility of the block members of the present invention additionally lend the user to custom creating fire pit or barbeque grill accessories, trays or tables, or even integral seats. For example, a table may be formed by utilizing the barbeque grill 11 of
Claims
1. A modular assembly for use as a fire pit or outdoor grill, said modular assembly comprising:
- (a) a plurality of slab members; each of said slab members being comprised of an upper surface, a lower surface, an inside surface, an outside surface, a front end surface and a rear end surface; said upper surface being generally parallel to said lower surface; said upper surface of said slab member having a first top notch and a second top notch, said first top notch and said second top notch each extending from said outside surface to said inside surface; said first notch being located in proximity to said front end surface, and said second notch being located in proximity to said second end surface; said lower surface of said slab member having a first bottom notch and a second bottom notch, said first bottom notch and said second bottom notch each extending from said outside surface to said inside surface; said first bottom notch being located relative to said front end surface the same as the first top notch, and said second bottom notch being located relative to said second end surface the same as said second top notch;
- (b) said slab members being adapted to be assembled wherein there is a bottom course formed by positioning a first pair of said slab members parallel to each other, and separated by a distance equal to the spacing between the first and second notches; and positioning a second pair of said slab members parallel to each other but cross-wise to said first pair of slab members, and wherein said second pair of slab members are spaced such that said bottom notches in said second pair of slab members dovetail with said top notches of said first pair of slab members;
- (c) a plurality of successive courses, each of said successive courses comprising a primary pair of said slab members and a secondary pair of said slab members; said primary pair of slab members being oriented parallel to said first pair of slab members of said bottom course, and assembled to dovetail with a course below, said course below comprising either said first pair of slab members of said bottom course or a secondary pair of slab members of one of said successive courses; and positioning said secondary pair of slab members parallel to each other but cross-wise to said primary pair of slab members, and wherein said secondary pair of slab members are spaced such that said bottom notches in said secondary pair of slab members dovetail with said top notches of said first pair of slab members.
2. The modular assembly according to claim 1, wherein said inside surface and said outside surface of said slab member are generally parallel to each other and are orthogonal to said upper surface and said lower surface; and wherein said front end surface and said rear end surface of said slab member are generally parallel to each other and are orthogonal to said inside surface and said outside surface; and wherein said surfaces form an elongated block having a rectangular cross-section.
3. The modular assembly according to claim 1, wherein at least a portion of any of said inside surface, said outside surface, said front end surface, and said rear end surface of said slab member are curved.
4. The modular assembly according to claim 1, wherein said inside surface of said slab member is also comprised of two or more orifices; and wherein said orifices of said primary pair of slab members and said orifices of said secondary pair of slab members comprising one of said successive courses each house a rod which protrudes away from said slabs; said rods supporting a bottom grill grate.
5. The modular assembly according to claim 4 wherein said bottom grill grate is capable of supporting a fire.
6. The modular assembly according to claim 5 wherein said bottom grill grate is removable.
7. The modular assembly according to claim 6 wherein said orifices of said primary pair of slab members and said orifices of said secondary pair of slab members of one of said successive courses each house a rod each house a rod which protrudes from said slab; said rods supporting a top grill grate.
8. The modular assembly according to claim 7 wherein said top grill grate permits cooking of food.
9. The modular assembly according to claim 8 wherein a plurality of additional courses is positioned below said bottom course, for use in creating an opening, each of said additional courses comprising:
- (a) a set of lateral slab members and a primary pair of slab members, said set of lateral slab members comprising one slab member and two spacer slab members, each of said spacer slabs comprising an upper surface, a lower surface, an inside surface, an outside surface, a front end surface and a rear end surface; said upper surface being generally parallel to said lower surface; said upper surface of said spacer slab member having a top notch, said top notch extending from said outside surface to said inside surface; said top notch being located approximately midway between said front end surface and said rear end surface; said lower surface of said spacer slab member having a bottom notch, said bottom notch extending from said outside surface to said inside surface; said bottom notch being located relative to said front end surface the same as said top notch;
- (b) positioning said two spacer slabs of said set of lateral slab members to be in line with each other such that the distance between said top notch of each spacer slab is equal to the distance between said first and second notches of said slab member; and positioning said slab member of said set of lateral slab members parallel to said in-line spacer slabs and at a distance such that said top notches in said set of lateral slab members dovetails with a course above, said course above comprising either said first pair of slab members of said bottom course or a primary pair of slab members of one of said additional courses; and positioning said primary pair of slab members parallel to each other but cross-wise to said set of lateral slab members, and wherein said primary pair of slab members are spaced such that said top notches of said primary pair of slab members dovetail with said bottom notches of said set of lateral slab members.
10. The modular assembly according to claim 9, wherein said inside surface and said outside surface of said spacer slab member are generally parallel to each other and are orthogonal to said upper surface and said lower surface; and wherein said front end surface and said rear end surface of said spacer slab member are generally parallel to each other and are orthogonal to said inside surface and said outside surface; and wherein said surfaces form an elongated block having a rectangular cross-section.
11. The modular assembly according to claim 9, wherein at least a portion of any of said inside surface, said outside surface, said front end surface, and said rear end surface of said spacer slab member is curved.
12. The modular assembly according to claim 9, wherein said inside surface, said outside surface, said front end surface, and said rear end surface of said spacer slab member smoothly transition to form a single curved continuous surface.
13. The modular assembly according to claim 9 wherein said second pair of slab members of a top course are also connected with a pair of plain slab members, and wherein said top course is comprised of the last of said plurality of successive courses; said plain slab member being constructed the same as said slab member but without said first top notch and said second top notch.
14. The modular assembly according to claim 9 wherein said second pair of slab members of a top course are also connected with a plain slab member, and wherein said top course is comprised of the last of said plurality of successive courses; said plain slab member being constructed the same as said slab member but without said first top notch and said second top notch.
15. The modular assembly according to claim 9 wherein a base course is positioned below said bottom course, said base course comprising a base pair of slab members which dovetail with said bottom course, and a base pair of plain slab members, wherein said first bottom notch and said second bottom notch of said plain slab members dovetail with said first bottom notch and-said second bottom notch of said base pair of slab members.
16. The modular assembly according to claim 15 wherein said top notches and said bottom notches are rectangular shaped.
17. The modular assembly according to claim 15 wherein said top notch comprises a notch with a male protrusion, and wherein said bottom notch comprises a notch with a female indentation; said male protrusion and female indentation being capable of interlocking.
18. The modular assembly according to claim 17 wherein said male protrusion and said female indentation are conically shaped.
19. The modular assembly according to claim 17 wherein said male protrusion and said female indentation are V-shaped.
20. The modular assembly according to claim 17 wherein said male protrusion and said female protrusion are cylindrically shaped.
21. The modular assembly according to claim 17 wherein said male protrusion and said female protrusion have a hemispherical shape.
22. The modular assembly according to claim 17 wherein said male protrusion and said female protrusion comprise a complex convex shape.
23. The modular assembly according to claim 15 wherein said assembly further comprises a fume hood.
24. The modular assembly according to claim 23 wherein said fume hood rests on said top grill grate.
25. The modular assembly according to claim 23 wherein said fume hood rests on said top course.
26. The modular assembly according to claim 23 wherein said fume hood rests on said plain slab members.
27. The modular assembly according to claim 23 wherein said fume hood is mechanically attached to said plain slab members, said attachment means is from the group consisting of: protruding dowel pins; masonry screws; or anchors.
28. The modular assembly according to claim 23 wherein said fume hood is constructed from the group consisting of: copper; brass; ferrous alloy; bronze; aluminum; or flame proof composite material.
29. The modular assembly according to claim 28 wherein said composite material is from the group consisting of: phenolic resin; fiberglass; or carbon fiber reinforced epoxy.
30. The modular assembly according to claim 23 wherein said fume hood has insulated side handles.
31. The modular assembly according to claim 9 wherein said second pair of slab members of a top course are also connected with a transition slab member, and wherein said top course is comprised of the last of said plurality of successive courses; said transition slab member being constructed the same as said slab member but with said second top notch being located along said top surface at a position in between said first bottom notch and said second bottom notch.
32. The modular assembly according to claim 31 wherein said fume hood is constructed by assembling a plurality of open hood courses, each of said open fume courses comprising a pair of short slab members and said set of lateral slab members, said short slab member being formed like a slab member and having a length shorter than said slab member.
33. The modular assembly according to claim 32 wherein said assembly of said fume hood further comprises a plurality of closed hood courses, each of said closed fume courses comprising a pair of said slab members and a pair of said short slab members.
34. The modular assembly according to claim 33 wherein said assembly of said fume hood further comprises a plurality of telescoping hood courses, each of said telescoping fume courses comprising a pair of short slab members and a pair of variable length slab members, said variable length slab members being formed like a slab member and having any length which is shorter than said slab member.
35. The modular assembly according to claim 8 wherein said top grill grate is constructed from the group consisting of: copper; carbon steel; cast iron; stainless steel; bronze; brass; aluminum; high temperature glass; or opaque glazed high impact ceramic.
36. The modular assembly according to claim 8 wherein said top grill grate is a gas burner.
37. The modular assembly according to claim 34 wherein said slab members, said spacer slab members, said plain slab members, said short slab members, and said variable length slab members are formed of cast concrete.
38. The modular assembly according to claim 37 wherein said cast concrete is surface pigmented.
39. The modular assembly according to claim 37 wherein said surface pigment is from the group consisting of: particles of metal oxide; inorganic pigments; organic pigments; and organic dyes.
40. The modular assembly according to claim 39 wherein said concrete is cast to mimic the appearance of material from the group consisting of: stone; brick; and decorative mosaic tile.
41. The modular assembly according to claim 40 wherein said cast concrete comprises air entrained concrete.
42. The modular assembly according to claim 41 wherein said cast concrete comprises reduced density concrete.
43. The modular assembly according to claim 42 wherein said cast concrete comprises thermally insulative concrete.
44. A modular assembly for use as a fire pit or outdoor grill, said modular assembly comprising:
- (a) a plurality of slab members; each of said slab members being comprised of an upper surface, a lower surface, an inside surface, an outside surface, a front end surface and a rear end surface to form an elongated block having a rectangular cross-section; said upper surface of said slab member having a first top notch and a second top notch, said first top notch and said second top notch each extending from said outside surface to said inside surface; said first notch being located in proximity to said front end surface, and said second notch being located in proximity to said second end surface; said lower surface of said slab member having a first bottom notch and a second bottom notch, said first bottom notch and said second bottom notch each extending from said outside surface to said inside surface; said first bottom notch being located relative to said front end surface the same as the first top notch, and said second bottom notch being located relative to said second end surface the same as said second top notch;
- (b) said slab members being adapted to be assembled wherein there is a bottom course formed by positioning a first pair of said slab members parallel to each other, and separated by a distance equal to the spacing between the first and second notches; and positioning a second pair of said slab members parallel to each other but cross-wise to said first pair of slab members, and wherein said second pair of slab members are spaced such that said bottom notches in said second pair of slab members dovetail with said top notches of said first pair of slab members;
- (c) a plurality of successive courses, each of said successive courses comprising a primary pair of said slab members and a secondary pair of said slab members; said primary pair of slab members being oriented parallel to said first pair of slab members of said bottom course, and assembled to dovetail with a course below, said course below comprising either said first pair of slab members of said bottom course or a secondary pair of slab members of one of said successive courses; and positioning said secondary pair of slab members parallel to each other but cross-wise to said primary pair of slab members, and wherein said secondary pair of slab members are spaced such that said bottom notches in said secondary pair of slab members dovetail with said top notches of said first pair of slab members.
Type: Application
Filed: May 22, 2009
Publication Date: Dec 31, 2009
Inventor: Wayne Love (Norphlet, AR)
Application Number: 12/454,932
International Classification: F24B 1/18 (20060101); E04C 1/00 (20060101); F24B 1/193 (20060101);