Quick assembly grill and method

Abstract

The present invention is embodied in a grill configured for quick assembly, a method of partially pre-assembling the grill for shipping from the factory in a container, and a method of assembling the grill when removed from the shipping container. The grill comprises a firebox assembly for mounting on a cart assembly, the cart assembly having first and second support assemblies and at least one linking member interconnecting them. A hinge or pivot in the mid-portion of the linking member divides it into first and second linking member portions, and the opposite ends of the linking member portions are pivotally connected by hinges or the like to the first and second support assemblies. The linking member holds the first and second support assemblies together in a partially pre-assembled state, and the pivotal connections of the linking member portions allow the two assemblies to be folded for packaging in a shipping container. When removed from the container, the pivotal connections of the linking member portions allow the first and second support assemblies to be unfolded, with the linking member holding the two support assemblies in approximately the proper position with respect to each other and to the firebox assembly for assembly of the grill, thus allowing for easier and quicker grill assembly by one person. Alternatively, the linking member can itself be a support assembly with the first and second support assemblies pivotally attached to opposite ends of the linking member.

1 - 40 . (canceled) 
     
     
         41 : A grill comprising:
 a firebox assembly comprising:
 a firebox base, and 
 a firebox hood pivotally connected to the firebox base; and 
   a cart assembly for supporting the firebox assembly, the cart assembly comprising:
 a first support assembly configured to be joined to the firebox base, 
 a second support assembly configured to be joined to the firebox base, 
 a linking member interconnecting the first and second support assemblies, the linking member comprising
 a first linking member portion having an end that is pivotally attached to the first support assembly, 
 a second linking member portion having an end that is pivotally attached to the second support assembly, and 
 a hinge connecting the first linking member portion and the second linking member portion; 
 
   wherein the first linking member portion and the second linking member portion can be folded about the hinge to convert the cart assembly from a storage configuration, in which the first linking member portion and the second linking member portion are folded, to an assembled configuration, in which the first linking member portion and the second linking member portion are unfolded to a position suitable for supporting the firebox assembly.   
     
     
         42 : The grill of  claim 41 , wherein the linking member further comprises a locking mechanism, proximate the hinge, that helps to maintain the cart assembly in the assembled configuration when the first linking member portion and the second linking member portion are unfolded. 
     
     
         43 : The grill of  claim 42 , wherein the locking mechanism comprises:
 a recess formed in the first linking member portion; and   a protrusion formed on the second linking member portion;   wherein the protrusion is sized and configured to be received in the recess with a friction fit when the first linking member portion and the second linking member portion are unfolded.   
     
     
         44 : The grill of  claim 43 , wherein the protrusion is a cylindrical nub. 
     
     
         45 : The grill of  claim 44 , wherein the protrusion is mounted on a block extension. 
     
     
         46 : The grill of  claim 42 , wherein the locking mechanism comprises:
 a locking arm mounted along a length of the first linking member portion; and   a locking rod mounted substantially within the second linking member portion and perpendicular to the locking arm;   wherein a tip of the locking rod extends through a hole formed in the second linking member portion; and   wherein the tip of the locking rod is configured to pass under the locking arm and engage a hole formed in the locking arm as the first linking member portion and the second linking member portion are unfolded.   
     
     
         47 : The grill of  claim 41 , wherein the linking member is configured to hold the cart assembly in the assembled configuration when the first linking member portion and the second linking member portion are unfolded to facilitate installation of the firebox assembly on the cart assembly. 
     
     
         48 : The grill of  claim 47 , wherein the linking member provides substantially no lateral support between the first support assembly and the second support assembly after installation of the firebox assembly on the cart assembly. 
     
     
         49 : The grill of  claim 41 , wherein the first linking member portion and the second linking member portion are configured to pivot downwardly, relative to the assembled configuration of the cart assembly, when the linking member is folded to convert the cart assembly to a storage configuration. 
     
     
         50 : The grill of  claim 41 , wherein the first linking member portion and the second linking member portion are configured to pivot inwardly, relative to the assembled configuration of the cart assembly, when the linking member is folded to convert the cart assembly to a storage configuration. 
     
     
         51 : The grill of  claim 41 , further comprising one or more grill members attached to the cart assembly or the firebox assembly, wherein each of the one or more grill members includes a keyhole opening comprising:
 a larger opening, sized and configured to receive a head of a threaded fastener partially pre-inserted into the cart assembly or the firebox assembly, and   a smaller opening, contiguous with the larger opening, and sized and configured to slide under the head and around a shaft of the threaded fastener.   
     
     
         52 : The grill of  claim 51 , wherein:
 one of the one or more grill members is a first cart brace and a second of the one or more grill members is a second cart brace;   each of the first and second cart braces comprises
 a first end attached to the first support assembly, and 
 a second end attached to the second support assembly; and 
   the first and second cart braces are spaced from each other on opposite sides of the cart assembly.   
     
     
         53 : The grill of  claim 51 , wherein one of the one or more grill members is a cart shelf having a first edge attached to the first support assembly and a second edge configured to be attached to the second support assembly. 
     
     
         54 : The grill of  claim 53 , wherein the first edge of the cart shelf is pivotally attached to the first support assembly so that the cart shelf can be pivoted to convert the cart shelf from a storage configuration, in which the cart shelf is folded onto the first support assembly, to an assembled configuration, in which the cart shelf is positioned so that the second edge can be attached to the second support assembly. 
     
     
         55 : The grill of  claim 54 , further comprising a side cart panel having:
 a first edge configured to be attached to the first support assembly;   a second edge configured to be attached to the second support assembly; and   a bottom edge pivotally attached to a side edge of the cart shelf so that the side cart panel can be pivoted to convert the side cart panel from a storage configuration, in which the side cart panel is folded onto the cart shelf, to an assembled configuration, in which the side cart panel is positioned so that the first edge can be attached to the first support assembly and the second edge can be attached to the second support assembly.   
     
     
         56 : The grill of  claim 51 , wherein one of the one or more grill members is a side cart panel having a first edge attached to the first support assembly and a second edge attached to the second support assembly. 
     
     
         57 : The grill of  claim 51 , wherein one of the one or more grill members is a side table having a first edge attached to the firebox assembly. 
     
     
         58 : The grill of  claim 41 , further comprising a second linking member interconnecting the first support assembly and the second support assembly;
 wherein the second linking member comprises
 a first linking member portion having an end that is pivotally attached to the first support assembly; 
 a second linking member portion having an end that is pivotally attached to the second support assembly; and 
 a hinge connecting the first linking member portion and the second linking member portion. 
   
     
     
         59 : The grill of  claim 58 , further comprising a third linking member and a fourth linking member interconnecting the first support assembly and the second support assembly;
 wherein the third linking member and fourth linking member each comprise
 a first linking member portion having an end that is pivotally attached to the first support assembly; 
 a second linking member portion having an end that is pivotally attached to the second support assembly; and 
 a hinge connecting the first linking member portion and the second linking member portion. 
   
     
     
         60 : The grill of  claim 41 , further comprising:
 a side burner valve assembly having a partially inserted, threaded fastener; and   a side table having a keyhole opening formed therein to receive the threaded fastener and secure the side burner valve assembly to the side table;   wherein the keyhole opening includes
 a larger opening, sized and configured to receive a head of the threaded fastener; and 
   a smaller opening, contiguous with the larger opening, and sized and configured to slide under the head and around a shaft of the threaded fastener.