U.S. patent application number 09/808819 was filed with the patent office on 2002-09-19 for gas burner.
Invention is credited to Gore, Hardial S., Paul, Depinder, Rehberg, Thomas R..
Application Number | 20020132205 09/808819 |
Document ID | / |
Family ID | 25199830 |
Filed Date | 2002-09-19 |
United States Patent
Application |
20020132205 |
Kind Code |
A1 |
Gore, Hardial S. ; et
al. |
September 19, 2002 |
Gas burner
Abstract
A gas burner is provided that simulates wood burning fire and
the glowing amber effect of real wood or coal burning. The burner
comprises a burner pan which is covered by a refractory material.
Burner ports are formed through the refractory material.
Inventors: |
Gore, Hardial S.; (Buena
Park, CA) ; Rehberg, Thomas R.; (Anaheim, CA)
; Paul, Depinder; (Cerritos, CA) |
Correspondence
Address: |
CHRISTIE, PARKER & HALE, LLP
350 WEST COLORADO BOULEVARD
SUITE 500
PASADENA
CA
91105
US
|
Family ID: |
25199830 |
Appl. No.: |
09/808819 |
Filed: |
March 15, 2001 |
Current U.S.
Class: |
431/328 ;
431/326 |
Current CPC
Class: |
F23D 2203/103 20130101;
F23D 2203/105 20130101; F23D 2212/10 20130101; F23D 2203/106
20130101; F23D 2203/1017 20130101; F23D 14/16 20130101; F23D
2212/20 20130101 |
Class at
Publication: |
431/328 ;
431/326 |
International
Class: |
F23D 014/12; F23D
014/16 |
Claims
1. A burner comprising: a pan comprising a base surrounded by
walls; a screen surface mounted within the pan and spaced apart
from the base; a ceramic board over the screen, the board having a
first surface opposite a second surface and peripheral edges there
between, wherein the second surface faces the screen; a metal strip
adjacent each edge; and a metallic foil sheet wrapped around the
second surface and edges exposing the first surface of the ceramic
board, wherein the foil extends between the screen and the ceramic
board and wherein the metal strips are coupled to the walls forming
a closed burner.
2. A burner as recited in claim 1 of the burner further comprising
a plurality of openings formed through the foil and board defining
gas outlet ports.
3. A burner as recited in claim 1 wherein a portion of the ceramic
board is convex in cross-section.
4. A burner as recited in claim 1 wherein the metallic strips are
made from a weldable metallic material, wherein the walls are made
from a weldable metallic material, and wherein the walls are welded
to the strips and whereby the foil between the strips and walls
flows during welding and mixes with the strips and walls.
5. A burner as recited in claim 1 wherein the foil is attached to
the board using an adhesive.
6. A burner as recited in claim 1 wherein the metallic foil is made
from aluminum.
7. A burner as recited in claim 1 wherein the foil is glued to the
walls.
8. A burner as recited in claim 1 further comprising a plurality of
fasteners fastening the board to the screen surface.
9. A burner as recited in claim 1 wherein the first surface of the
ceramic board comprises carvings.
10. A burner as recited in claim 1 wherein the board comprises a
density, wherein the density of the board varies through the
thickness of the board.
11. A burner as recited in claim 10 wherein the density of the
board proximate the first surface is less than the density of the
board proximate the second surface.
12. A burner comprising: a pan comprising a base surrounded by
walls; a screen surface mounted within the pan and spaced apart
from the base; a ceramic board over the screen, the board having a
first surface opposite a second surface and peripheral edges there
between, wherein the second surface faces the screen; a metal sheet
wrapped around the second surface and edges exposing the first
surface of the ceramic board, wherein the metal sheet extends
between the screen and the ceramic board and wherein the metal
sheet is attached to the walls forming a closed burner.
13. A burner as recited in claim 12 wherein the metal sheet is
welded to the walls.
14. A burner as recited in claim 12 wherein the sheet is attached
to the walls using an adhesive.
15. A burner as recited in claim 12 the burner further comprising a
plurality of openings formed through the metal sheet and board
defining gas outlet ports.
16. A burner as recited in claim 12 wherein the first surface of
the ceramic board is carved.
17. A burner as recited in claim 12 further comprising a plurality
of fasteners fastening the board to the screen surface.
18. A burner comprising: a pan having a plurality of walls; a
ceramic board having a first surface opposite a second surface and
a thickness there through; a plurality of ports formed through the
thickness; and a slot formed on the first surface, wherein the pan
walls are fitted within the slot.
19. A burner as recited in claim 18 wherein the walls are in the
slots with a ceramic fiber adhesive.
20. A burner comprising: a pan having a plurality of walls; a
ceramic board having a first surface opposite a second surface and
a thickness there through, the ceramic board being mounted over the
pan; a plurality of ports formed through the thickness; and a
plurality of legs extending from the first surface and adjacent to
the walls.
21. A burner as recited in claim 20 wherein the plurality of legs
are bonded to the walls.
22. A burner as recited in claim 20 wherein one of said plurality
of legs intersects another of said plurality of legs.
23. A burner as recited in claim 20 wherein the number of legs is
equal to the number of pan walls and wherein each leg is adjacent
to one of said pan walls.
24. A burner as recited in claim 20 further comprising a plurality
of second legs, each wall is sandwiched between a second leg and a
leg extending from the first surface.
25. A burner as recited in claim 24 wherein the plurality of second
legs intersect each other.
26. A method for forming a closed burner comprising: introducing a
pan having a base and surrounding walls; introducing a ceramic
board having a first surface opposite a second surface and a
peripheral edge there between; attaching at least a metallic strip
to the peripheral edge; covering the second surface, and edge with
a foil; and attaching the foil to the walls exposing the first
surface of the ceramic board forming a closed burner.
27. A method as recited in claim 26 wherein the step attaching
comprises the step of welding the at least one strip to the
walls.
28. A method as recited in claim 26 wherein the foil is made from
aluminum.
29. A method as recited in claim 26 wherein the step of attaching
comprises bonding the foil the walls using an adhesive.
30. A method as recite in claim 26 further comprising the step of
carving the first surface of the board.
31. A method as recited in claim 26 wherein the step of introducing
a ceramic board and the surrounding steps comprises: shaping a foil
in the shape complementary of the desired board second surface and
peripheral edge; placing the at least one metal strip within the
foil pan along the surface of the foil complementary to the
peripheral edge; pouring a ceramic material in the foil pan; and
baking the foil with at least one strip and ceramic material
forming a ceramic board having a shape complementary to the foil
and having the at least one metallic strip adjacent to its
peripheral edge, and the at least one strip and the second surface
of the board surrounded by the foil.
32. A method for forming a closed burner comprising: introducing a
pan having a base and surrounding walls; introducing a ceramic
board having a first surface opposite a second surface and a
peripheral edge there between; covering the second surface and edge
with sheet metal; and attaching the foil to the walls exposing the
first surface of the ceramic board forming a closed burner.
33. A method as recited in claim 32 wherein the step 7 attaching
comprises the step of welding the sheet metal to the walls.
34. A method as recited in claim 32 wherein the step of attaching
comprises gluing the sheet metal to the walls using an
adhesive.
35. A method as recited in claim 32 further comprising forming
holes in the sheet metal adjacent the second surface for defining
gas outlets.
36. A method as recited in claim 32 further comprising the step of
carving the first surface of the ceramic board.
37. A method as recited in claim 32 wherein the step of introducing
a ceramic board and the surrounding steps comprise: shaping a the
sheet metal in the shape complementary of the desired board second
surface and peripheral edge; pouring a ceramic material in the
shaped sheet metal; and baking the shaped sheet metal with the
ceramic material forming a ceramic board having a shape
complementary to the shaped sheet metal and having its peripheral
edge and the second surface of the board surrounded by the
foil.
38. A burner comprising: a concrete board having a thickness and
ports defined there through; and a pan comprising a peripheral
surface, wherein a portion of the peripheral surface is embedded in
the concrete board, wherein the concrete board and pan define an
enclosed burner and wherein the concrete defines an exposed surface
of the burner.
39. A burner as recited in claim 38 further comprising a ceramic
board embedded in the concrete board.
40. A burner as recited in claim 38 wherein the ceramic board
comprises ports aligned with ports formed on the concrete
board.
41. A burner comprising: a refractory board comprising a refractory
adhesive; and a pan comprising a peripheral surface, wherein a
portion of the peripheral surface is embedded in the refractory
board, wherein the refractory board and pan define an enclosed
burner and wherein the refractory board defines an exposed surface
of the burner.
42. A burner as recited in claim 41 further comprising a ceramic
board embedded in the refractory board.
43. A burner as recited in claim 41 wherein the ceramic board
comprises ports aligned with ports formed on the refractory
board.
44. A method for making a burner comprising the steps of: providing
a mold having an inner surface having a desired shape; pouring a
refractory material in the mold; providing a burner pan comprising
a peripheral surface; embedding the peripheral surface of the pan
in the refractory material; curing the refractory material forming
an enclosed burner; and removing the mold.
45. A method as recited in claim 44 wherein the step of providing
comprises providing a mold having at least a protrusion extending
to a level, and wherein the step of pouring comprises pouring the
refractory material to a level lower than the level of the
protrusion.
46. A method as recited in claim 45 wherein the step of pouring
comprises pouring concrete.
47. A method a recited in claim 45 wherein the step of pouring
comprises pouring a refractory adhesive.
48. A method as recited in claim 45 further comprising the steps
of: providing a ceramic board having at least a port; placing the
ceramic board into the mold such that the port is penetrated by the
protrusion prior to the step of pouring.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a gas burner that simulates
a glowing amber effect of wood or coal burning.
BACKGROUND OF THE INVENTION
[0002] Gas burners are currently used in many gas fireplaces in
combination with artificial logs for producing flames. While the
artificial logs may give the appearance of realistic real wood
burning logs, in many instances, the burner itself is visible,
detracting from the realistic fireplace burning appearance. As
such, a gas burner is desired that provides the glowing amber
effect of real wood or coal burning so as to not detract from the
realistic appearance of a gas fireplace.
SUMMARY OF THE INVENTION
[0003] A gas burner is provided that simulates wood burning fire
and the glowing amber effect of real wood or coal burning. In an
exemplary embodiment, the burner has a rectangular shaped
cross-section. However, the cross-sectional shape of the burner may
be round, square or a combination thereof.
[0004] In the exemplary embodiment, the burner comprises a pan in
the form of a rectangular open box. The pan comprises a base
surrounded by two opposite side walls and two opposite end walls.
An elongate support screen having a channel shaped cross-section,
i.e., a U-shaped cross-section having opposite legs and a web there
between, is placed within the pan such that the legs of the screen
rest against the pan.
[0005] A ceramic material board is rested on the web of the screen
to form the upper surface of the burner while fully enclosing the
burner. A ceramic material board is used because it has low thermal
expansion, can withstand high temperatures, and has an irregular
surface which can be easily modified to simulate coal or wood
burning ambers.
[0006] The ceramic board may be welded or adhered to the side walls
of the burner pan using an appropriate adhesive. In one embodiment,
on the side edges and bottom surface of the board are covered with
a covering made from a weldable material. The covering is then
welded to the walls of the pan. In a preferred embodiment, weldable
strips are placed over the edge surface of the ceramic board and
the strips and lower surface of the board are covered by aluminum.
The strips are then welded to the walls of the burner pan for
adhering the board to the burner.
[0007] A better seal can be obtained between the ceramic board and
the walls of the burner pan by tying the ceramic board to the
screen. This can be accomplished by screwing the ceramic board to
the screen web, better sealing was achieved.
[0008] In another embodiment, a ceramic board is formed having a
slot on its bottom surface defining a shape complementary to the
shape defined by the end and side walls of the burner pan. The
ceramic board is fitted over the burner pan such that the end and
side walls of the pan are fitted within the slot. A ceramic
adhesive or silicone is preferably placed within the slot prior to
installation of the board over the pan.
[0009] In a further alternate embodiment shown the board is formed
with a leg or legs extending proximate its periphery. The board is
mounted over the burner pan with the leg or legs extending adjacent
to the walls of the burner pan. The leg or legs are bonded to the
pan walls preferably using a ceramic adhesive or silicone.
[0010] Burner ports are formed through the ceramic board and
through the covering if used to allow for the gas to escape there
through. The size and location as well as density of the ports in
the in the covering and board can be tailored so as to create
different flame patterns.
DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a cross-sectional view of a burner of the present
invention.
[0012] FIG. 2 is an exploded perspective view of the burner shown
in FIG. 1.
[0013] FIG. 3 is a perspective of a covering used to cover the
ceramic board used in the burners of the present invention.
[0014] FIG. 4 is a cross-sectional view of another embodiment
burner of the present invention.
[0015] FIG. 5 is a cross-sectional view of a further embodiment
burner of the present invention.
[0016] FIG. 6A is a an exploded view of an open embodiment burner
of the present invention.
[0017] FIG. 6B is a cross-sectional view of the embodiment shown in
FIG. 6A.
[0018] FIG. 7 is a cross-sectional view of another embodiment of
the present invention.
[0019] FIG. 8 is a cross-sectional view of yet another embodiment
burner of the present invention.
[0020] FIG. 9 is a cross-sectional view of yet further embodiment
burner of the present invention.
[0021] FIG. 10 is a perspective view of an alternate embodiment
burner of the present invention having a concrete upper
portion.
[0022] FIG. 11 is a perspective view of an exemplary mold used to
form the concrete upper portion of the burner shown in FIG. 10.
[0023] FIG. 12 is a perspective view of a further alternate
embodiment burner of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0024] A gas burner 10 is provided that simulates wood burning fire
and the glowing amber effect of real wood or coal burning (FIG. 1).
In an exemplary embodiment, the burner has a rectangular shaped
cross-section. However, the cross-sectional shape of the burner may
be round, square or a combination thereof.
[0025] In an exemplary embodiment, the burner comprises a pan 12 in
the form of a rectangular open box. The pan comprises a base 14
surrounded by two opposite side walls 16 and two opposite end walls
18 (FIGS. 1 and 2). An elongate support screen 20 having a channel
shaped cross-section, i.e., a U-shaped cross-section, is placed
within the pan. In essence, the screen comprises two leg portions
22 and a web 24 there between. In a preferred embodiment, the
U-shaped screen is formed by taking an elongated strip of screen
material and bending its ends downward. When placed within the pan,
the legs 22 of this screen rest against the pan base 14. The length
of the screen 20 is preferably just slightly smaller than the
length of the pan 12 such that when it is placed within the pan,
the screen occupies almost the entire length of the pan.
Preferably, the web portion of the screen is wide enough to span
almost the entire width of the pan. The screen may consist of
perforations 23 throughout the entire length and width of the
screen, as for example shown in FIG. 2, or may include only
sections of perforations surrounded by sections of solid material.
The perforated sections of the screen should be positioned so as to
provide a passage for the gas to flow from the pan to the burner
ports.
[0026] A ceramic material board 26 is rested on the web 24 of the
screen to form the upper surface of the burner while fully
enclosing the burner. The ceramic board may have a flat upper
surface 28 (FIG. 1) or a convex upper surface 28 (FIG. 4). A
ceramic material board is used because it has low thermal
expansion, can withstand high temperatures, and has an irregular
surface which can be easily modified to simulate coal or wood
burning ambers. The ceramic board comprises an upper surface 28, a
lower surface 30, and side edge surfaces 32 and end edge surfaces
33 between the upper and lower surfaces (FIGS. 1 and 2).
[0027] The terms "upper," "lower," "upward" and "downward" as used
herein are relative terms and do not necessarily denote the actual
position of an element. For example, an "upper" member may be
located lower than a "lower" member.
[0028] In one embodiment, the ceramic board lower surface 30 and
side and end edge surfaces 32, 33 are wrapped with a heat and flame
resistant material 34 forming a covering 35. Preferably an aluminum
foil having a thickness of preferably 2 to 13 mils is used to form
the covering 35. Aluminum foil is the preferred covering for the
ceramic board, because it is easily pliable to a desired shape and
it can be easily cut and drilled to form the gas ports 40. When the
ceramic board is rested on the screen, the lower surface 30 of the
ceramic board covered with the covering faces toward the
screen.
[0029] If the covering is made from a non-weldable material, e.g.,
aluminum foil, then strips 36 of a weldable material, as for
example steel, are placed along the side edge surfaces 32 of the
ceramic board for providing weldable surfaces. Weldable strips 38
are also placed along the end edge surfaces 33 of the ceramic
board. The covering 35 is wrapped over the metal strips 36, 38. The
covering and weldable strips 36, are spot welded to the side walls
16 and end walls 18 of the pan thereby forming a sealed enclosure
with the pan. In such case, during welding, the non-weldable
material, e.g., the aluminum, the weldable strips and the side and
end walls of the pan flow and mix with each other such that when
they cool, the strips (if used) and pan side and end walls are
welded to each other.
[0030] If the covering 35 is made from a weldable material, as for
example steel, the covering is spot welded to the side walls 16 and
end walls 18 of the pan thereby forming a sealed enclosure with the
pan. A heat and flame resistant sealant may also be applied between
the board, covering, strips and pan walls to provide a further seal
at the interface between the board and the pan walls.
[0031] Burner ports 40 are formed through the ceramic board and
through the covering to allow for the gas to escape there through.
The size and location as well as density of the ports in the in the
covering and board can be tailored so as to create different flame
patterns.
[0032] In an alternate embodiment, instead of spot welding the
covering 35 to the pan side and end walls, the covering may be
attached to the side and end walls of the burner pan using a
suitable adhesive. Sheet metal screws (not shown) may also be used
which penetrate through the metal strips if incorporated. If the
covering is adhered to the walls of the pan, then weldable strips
are not necessary.
[0033] Applicant has discovered that a better seal can be obtained
between the ceramic board and the walls of the burner pan by tying
the ceramic board to the screen. Specifically, applicant has
discovered that by screwing the ceramic board to the screen web,
better sealing was achieved. Preferably four screws 60 such as
sheet metal screws are screwed through the thickness of the ceramic
board and into the screen web tying the ceramic board to the screen
(FIGS. 1 and 2). A washer 62 is preferably used with each screw
such that the washer is sandwiched between the head 64 of each
screw and the ceramic board for providing support to the screw
head. Preferably, countersinks 66 are formed to accommodate the
screws so that the heads are flush with the upper surface of the
ceramic board.
[0034] In a preferred embodiment, the ceramic board, has a density
of preferably 16 lb. per cubic foot, and a thickness of about half
inch thick. Once cut to the desired size, the ceramic board is
dipped into a colloidal silica solution to get more strength. The
board is then dried into an oven for about one to two hours at
about 500.degree. F. The covering is preferably adhered to the
ceramic board using an adhesive.
[0035] In an alternate embodiment, the density of the ceramic board
may be made to vary through its thickness. Preferably, the upper
surface of the board is made to have a lower density while the
lower surface if the board is made to have a higher density.
Preferably, the density of the upper surface of the ceramic board
is as low as possible such that it can glow when subjected to heat.
An exemplary board may be made by positioning a lower density board
on top of a higher density board.
[0036] In a one embodiment, the exposed surface of the ceramic
board is carved into small uneven sections, preferably having a
size of about 1/2".times.1/2", with each carving having a depth of
about {fraction (3/16)}". After a desired carved pattern is
achieved on the ceramic board, ports may then be drilled on the
board and covering if so desired. When heated, the carvings provide
the appearance of ashes.
[0037] In a further alternate embodiment, the covering 35, is
formed in the shape of a pan 42 (FIG. 3). If the covering is made
from aluminum foil, weldable material strips 36, 38 are then placed
within the pan shaped covering along the inner walls of the shaped
pan. Alternatively, a weldable material frame, as for example a
steel frame, may be used instead of the strips. Ceramic material is
then poured within the confines of the foil pan and then baked to
form the ceramic board. Ports are formed as necessary though the
covering and through the thickness of the ceramic material.
[0038] In an alternate embodiment, the screen legs 22 may be
attached to the side walls 18 of the burner pan without contacting
the base of the pan as shown in FIG. 4. In yet a further
embodiment, support brackets may be formed extending from a base
116 of a pan as shown in FIG. 5. The screen 20 is then attached to
the support brackets. When the brackets are extending from the base
of the burner pan, the screen 20 having a cross-sectional channel
shape may be mounted over the brackets such that each leg 22 of the
screen is fitted between a bracket 52 and a burner pan side wall
116. In the exemplary embodiment shown in FIG. 5, a pan is formed
from separate side walls 116 and a separate base 114. The base 114
has two legs 50 extending from the ends of the base, each leg
spanning the length of the base. The two legs are preferably formed
by bending the opposite end portions of the base. An L-shaped
bracket 52 comprising a first leg 54 and a second leg 56
perpendicular to the first leg is attached between each base leg 50
and each side wall 116. Specifically, the first leg 54 of each
bracket is sandwiched between a base leg 50 and a side wall 116
such that the second leg 56 of each bracket extends in a direction
away from its corresponding side wall. Each leg 22 of the support
screen is sandwiched between the bracket leg 52 and its
corresponding side wall 116. Each side wall 116, corresponding
bracket first leg 54 and corresponding base leg 50 are welded or
otherwise attached together forming the pan with a mounted
screen.
[0039] In yet a further alternate embodiment, the base of the
burner pan may be formed separate from the side and end walls of
the base. The sides and end wall are then attached to the base to
form the pan. For example, the side walls and end walls may form an
integral frame to which is attached a base to form the burner pan.
Alternatively, each side wall or end wall is separately attached to
the base.
[0040] In another embodiment, a ceramic board 70 is formed having a
slot 72 on its bottom surface 74 defining a shape complementary to
the shape defined by the end walls 76 and side walls 78 of a burner
pan 80 (FIGS. 6A and 6B). The ceramic board is fitted over the
burner pan such that the end and side walls of the pan are fitted
within the slot. A ceramic adhesive (or silicone) 82 is preferably
placed within the slot prior to installation of the board over the
pan. An adhesive is preferably used to bond the ceramic board to
the walls of the pan and to seal the interface between the ceramic
board and pan to prevent leakage of the gas through the interface.
With this embodiment, the depth of the slot should be shorter than
the height of the walls so that the lower surface 74 of the board
does not rest against the base 81 of the pan 80.
[0041] For a tighter fit, it is preferred that each section of the
slot interfacing with a wall of the pan has a shape complementary
to that wall and a thickness slightly greater than the thickness of
the wall. The slot can be formed by machining after formation of
the board and may be formed during manufacture by forming the board
using an appropriate mold.
[0042] In an alternate embodiment shown in FIG. 7, the board is
formed having a pair of legs, i.e., an inner leg 84 and an outer
leg 86 defining a slot 88 there between for accommodating the walls
of the pan. The slot has a shape complementary to the shape defined
by the end walls 76 and side walls 78 of the burner pan. For
example, if the walls of the burner define a rectangle than the
slot 88 defines a rectangle wherein each side of the rectangular
slot accommodates a wall of the burner pan. Alternatively four sets
of leg pairs are formed extending from the ceramic board such that
each set forms a slot for accommodating one of the walls of the
burner pan.
[0043] The ceramic board is mounted over the pan burner 80 such
that the walls are fitted within the slot(s), i.e., such that the
legs of the board stradle each wall. With this embodiment, the
board may be made to rest against the end and side walls by forming
the slot(s) 88 with a depth that is shorter than the height of the
burner pan end and side walls. In this regard, the base(s) 94 of
the slot(s) 88 will rest against the end and side walls of the
burner pan. Alternatively, the ceramic board may be made to rest
against the base of the pan by having the base(s) 90 of the inner
leg(s) 84 rest against the base 92 of the burner. This can be
accomplished by forming the slot(s) 88 with a depth at least as
high as the height of the end and side walls of the burner pan.
[0044] In a further alternate embodiment shown in FIG. 8, the board
70 if formed with only the inner leg(s) 84. With this embodiment,
when the board is mounted over the end walls 76 and side walls 78
of the burner pan, the inner leg(s) is (are) adjacent and interior
to the burner pan walls. The leg(s) is (are) preferably bonded to
the pan walls using a ceramic adhesive or silicone.
[0045] In yet a further alternate embodiment shown in FIG. 9, the
board 70 if formed with only the outer leg(s) 86. With this
embodiment, when the board is mounted over the end walls 76 and
side walls 78 of the burner pan, the outer leg(s) is (are) adjacent
and exterior to the burner pan walls. The leg(s) is (are)
preferably bonded to the pan walls using a ceramic fiber
adhesive.
[0046] With the embodiments shown in FIGS. 6-9 burner ports 100 are
formed through the ceramic board. The size and location as well as
density of the ports in the board can be tailored so as to create
different flame patterns.
[0047] In another embodiment, the burner may be formed with a
concrete board 110 as shown in FIG. 10. To burner concrete board is
formed in a mold 150 as for example shown in FIG. 11. The mold has
port forming members 152 as for example cylindrical members which
are used to form the ports 111. The geometry of the ports formed on
the concrete board is controlled by the geometry of the port
forming members. Concrete is poured on the mold to a level lower
than the height of the port forming members. Before the concrete
cures, a burner pan is pushed into the concrete such that the end
walls 116, 118 of the pan are immersed into the concrete. When the
concrete cures it is removed from the mold and forms a concrete
board attached to the burner pan defining a burner. The concrete
board upper surface 117 defines a surface of the burner.
[0048] The concrete may be of the same type that is used to form
the walls of the combustion chamber of a fireplace. In this regard
the concrete board 110 may be used to form a wall of the combustion
chamber as for example the combustion chamber floor. As such, the
burner will be hidden from view when used in a fireplace. In the
exemplary embodiment shown in FIG. 10, the concrete comprises
gravel, sand and cement.
[0049] In yet another embodiment as shown in FIG. 12, the burner is
formed with a concrete board 120 on which is embedded a ceramic
board 124. With this embodiment, a ceramic board is formed with the
requisite ports 126. The ceramic board is then fitted in the mold
such that the mold port forming members penetrate the ceramic board
ports 126. Concrete is then poured in the mold such that it
surrounds the concrete board. The concrete is poured to a level
lower than the level of the port forming members. Before the
concrete cures, a burner pan is pushed into the concrete such that
the end walls 116, 118 of the pan are immersed into the concrete.
When the concrete cures it forms the concrete board--having an
embedded ceramic board having an exposed surface 127--attached to
the burner pan defining a burner. The upper surface 128 of the
defined burner has a ceramic portion 130 surrounded by a concrete
portion 132.
[0050] The concrete board exposed surfaces 117, 132 of the burners
disclosed in FIGS. 10 and 12, respectively may be made to be rough
or smooth.
[0051] In yet further alternate embodiments, instead of using
concrete, the embodiments shown in FIGS. 10 and 12 may be formed
with a refractory adhesive.
[0052] With each of the aforementioned embodiments, a gas adapter
98 is attached to the burner pan, preferably at the base of the
burner pan or through a side wall of the pan for providing gas to
the burner. Gas enters the burner pan through the adapter and
escapes through the ports defined on the ceramic board for forming
a flame pattern.
[0053] To vary the desired pattern of coal simulation, the depth or
thickness of the ceramic board may be varied along its length and
width. Moreover, by adjusting the air that is provided to the
burner, the burner may be made to produce a range of effects from a
red hot coal look to a yellow flame.
[0054] Although the present invention has been described and
illustrated to respect to multiple embodiments thereof, it is to be
understood that it is not to be so limited, since changes and
modifications may be made therein which are within the full
intended scope of this invention as hereinafter claimed.
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