U.S. patent application number 10/384498 was filed with the patent office on 2004-09-09 for incorporation of particulates into fireplace articles.
Invention is credited to Early, Thomas Alfred, Lyons, David Charles, Patitz, Thomas Clark, Showalter, Glen James.
Application Number | 20040173204 10/384498 |
Document ID | / |
Family ID | 32927275 |
Filed Date | 2004-09-09 |
United States Patent
Application |
20040173204 |
Kind Code |
A1 |
Early, Thomas Alfred ; et
al. |
September 9, 2004 |
Incorporation of particulates into fireplace articles
Abstract
A gas fireplace article comprising a molded portion and a
particulate. The particulate providing an effect different from the
molded portion. An insert to fit within a recess of a gas fireplace
article. The insert including a particulate. Methods and
compositions for forming gas fireplace articles that include a
particulate.
Inventors: |
Early, Thomas Alfred; (Hager
City, WI) ; Lyons, David Charles; (Red Wing, MN)
; Patitz, Thomas Clark; (Menomonie, WI) ;
Showalter, Glen James; (Rochester, MN) |
Correspondence
Address: |
MERCHANT & GOULD PC
P.O. BOX 2903
MINNEAPOLIS
MN
55402-0903
US
|
Family ID: |
32927275 |
Appl. No.: |
10/384498 |
Filed: |
March 6, 2003 |
Current U.S.
Class: |
126/512 ;
431/125 |
Current CPC
Class: |
F24C 3/006 20130101 |
Class at
Publication: |
126/512 ;
431/125 |
International
Class: |
F24C 003/00 |
Claims
What is claimed is:
1. A gas fireplace article, comprising: a molded portion, the
molded portion comprising a ceramic fiber and a binder; and an
expandable particulate coupled to the molded portion, wherein the
expandable particulate provides an effect different from the molded
portion when heated.
2. The gas fireplace article of claim 1, the molded portion
comprising a compression molded material.
3. The gas fireplace article of claim 1, wherein the particulate
comprises a non-exfoliated vermiculite.
4. The gas fireplace article of claim 1, wherein an adhesive
couples the particulate to an outer surface of the molded
portion.
5. The gas fireplace article of claim 4, wherein the adhesive
comprises a ceramic adhesive.
6. The gas fireplace article of claim 5, further comprising a
volatile metallic salt.
7. A gas fireplace article comprising: a molded portion, the molded
portion defining a recess; and an insert sized to fit within the
recess, the insert comprising a ceramic fiber, a binder, and an
expandable particulate, wherein the expandable particulate provides
an effect different from the molded portion when heated.
8. The gas fireplace article of claim 7, the molded portion
comprising a compression molded material.
9. The gas fireplace article of claim 7, the expandable particulate
comprising a non-exfoliated vermiculite.
10. A molding composition for a gas fireplace article, the molding
composition comprising a mixture of a ceramic fiber, a binder, and
an expandable particulate.
11. The molding composition of claim 10, wherein the expandable
particulate is a non-exfoliated vermiculite.
12. The molding composition of claim 10, wherein the mixture is a
compression molding composition.
13. An insert for a fireplace article, the insert comprising: a
molded portion comprising a ceramic fiber and a binder; and an
expandable particulate coupled to the molded portion, wherein the
expandable particulate provides an effect different from the molded
portion when heated.
14. The replaceable insert of claim 13, wherein the expandable
particulate is a non-exfoliated vermiculite.
15. A method for simulating the burn of natural fire, the method
comprising: providing a gas fireplace article comprising a molded
portion and an expandable particulate coupled to the molded
portion; and altering the expandable particulate to allow the
expandable particulate to fall from the molded portion.
16. The method of claim 15, wherein the step of altering the
expandable particulate to allow the particulate to fall from the
molded portion comprises heating the particulate.
17. The method of claim 15, wherein the expandable particulate is a
non-exfoliated vermiculite.
18. The method of claim 15, further comprising the step of adhering
the expandable particulate to the molded portion with an
adhesive.
19. A method for forming a gas fireplace article, the method
comprising: forming a mixture of a ceramic fiber, a binder, and an
expandable particulate; providing the mixture of the ceramic fiber,
the binder, and the expandable particulate to a mold; and molding
the mixture into a desired shape.
20. The method of claim 19, wherein the particulate is a
non-exfoliated vermiculite.
21. The method of claim 19, wherein the step of molding the mixture
into a desired shape comprises compression molding the mixture.
Description
FIELD OF THE INVENTION
[0001] This invention relates to fireplaces. In addition, the
invention relates to incorporation of particulates into molded gas
fireplace articles.
BACKGROUND OF THE INVENTION
[0002] Gas fireplaces are an efficient method for providing warmth
and creating the appeal of a fire within a room. Also, gas
fireplaces have become commonplace in today's building trades for
both residential and commercial applications. Most new home
construction designs include at least one, and often several gas
fireplaces. Further, a significant number of remodeling projects
are focused on fireplaces.
[0003] The representation of the glow and look in such gas
fireplaces is desirable to simulate the effect created by a natural
fire. Previous systems created to provide a natural look of a
burning log or ember bed rely on contoured surfaces or the
incandescent glow from the material that forms the article, such
ceramic fibers or mineral wool. However, such systems have several
drawbacks.
[0004] First, upon heating of the previous articles, such as
artificial logs and burners, no materials are produced that expand
in size or fall away from the article to simulate the natural burn
or a log or the formation of burning embers and/or ash. Second,
these articles do not provide a method to replace expended
particulates that are incorporated into natural looking insert that
are integrated into the article. Third, previous systems fail to
incorporate particulates into the structure of the fireplace
article. Fourth, previous systems fail to provide the most
aesthetically appealing glow of fire because differential
incandescence is not utilized to emphasize the change in glow
intensity seen during the burn period of a natural fire. Further,
the differences in glow observed on specific portions of a natural
fire are not observed in gas fireplace articles.
SUMMARY OF THE INVENTION
[0005] Generally, the present invention relates to gas fireplaces.
One embodiment may include a gas fireplace article comprising a
molded portion. The molded portion comprises a ceramic fiber and a
binder. A particulate is coupled to the molded portion. The
particulate provides an effect different from the molded portion
when heated.
[0006] In another respect, the invention is directed to a gas
fireplace article comprising a molded portion. The molded portion
comprises a ceramic fiber and a binder. An expandable particulate
is coupled to the molded portion. The expandable particulate
provides an effect different from the molded portion when
heated.
[0007] In another respect, the invention is directed to a gas
fireplace article comprising. In another respect, the invention is
directed to a gas fireplace article comprising a molded portion.
The molded portion defines a recess. An insert is sized to fit
within the recess. The insert comprises a ceramic fiber, a binder,
and an expandable particulate. The expandable particulate provides
an effect different from the molded portion when heated.
[0008] In another respect, the invention is directed to an insert
for a fireplace article. The insert comprises a molded portion
comprising a ceramic fiber and a binder and an expandable
particulate coupled to the molded portion. The expandable
particulate provides an effect different from the molded portion
when heated.
[0009] In another respect, the invention is directed to a molding
composition for a gas fireplace article. The molding composition
comprises a mixture of a ceramic fiber, a binder, and an expandable
particulate.
[0010] In another respect, the invention is directed to a method
for simulating the burn of natural fire, the method comprising:
providing a gas fireplace article comprising a molded portion and
an expandable particulate coupled to the molded portion; and
altering the expandable particulate to allow the expandable
particulate to fall from the molded portion.
[0011] In another respect, the invention is directed to a method
for forming a gas fireplace article, the method comprising: forming
a mixture of a ceramic fiber, a binder, and an expandable
particulate; providing the mixture of the ceramic fiber, the
binder, and the expandable particulate to a mold; and molding the
mixture into a desired shape.
[0012] The above summary of the present invention is not intended
to describe each disclosed embodiment or every implementation of
the present invention. The figures and the detailed description
that follow more particularly exemplify these embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The invention may be more completely understood in
consideration of the following detailed description of various
embodiments of the invention in connection with the accompanying
drawings, in which:
[0014] FIG. 1 is a schematic front view of an embodiment of a gas
fireplace artificial log;
[0015] FIG. 2 is a schematic cross-sectional view of the gas
fireplace artificial log of FIG. 1;
[0016] FIG. 3 is a schematic cross-sectional view of a second
embodiment of a gas fireplace artificial log;
[0017] FIG. 4 is a schematic cross-sectional view of a compression
molded gas fireplace log;
[0018] FIG. 5 is a schematic cross-sectional view of the
compression molded gas fireplace artificial log of FIG. 4 having an
exposed inner portion;
[0019] FIG. 6 is a schematic cross-sectional view of a third
embodiment of a gas fireplace artificial log;
[0020] FIG. 7 is a schematic cross-sectional view of an embodiment
of a gas fireplace burner;
[0021] FIG. 8 is a schematic cross-sectional view of a second
embodiment of a gas fireplace burner; and
[0022] FIG. 9 is a cross-sectional view of a third embodiment of a
gas fireplace burner.
[0023] While the invention is amenable to various modifications and
alternative forms, specifics thereof have been shown by way of
example in the drawings and will be described in detail. It should
be understood, however, that the intention is not to limit the
invention to the particular embodiments described. On the contrary,
the intention is to cover all modifications, equivalents, and
alternatives failing within the spirit and scope of the
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] The present invention relates to gas fireplaces. In
particular, the present invention is directed to the use of
particulates in a molded log, burner, panel, or other article that
is subjected to heat in gas fireplace. The molded object can
include a ceramic fiber and a binder. The present invention may be
applicable to any gas fireplace such as a direct vent, a universal
vent, a B-vent, a horizontal/vertical-vent, a dual direct vent, a
multisided unit, or any gas insert, stove, or other gas-burning
device that utilizes heat and/or a flame. While the present
invention is not so limited, an appreciation of various aspects of
the invention will be gained through a discussion of the examples
provided below.
[0025] Referring to FIGS. 1 and 2, one embodiment of an article 100
molded in the shape of an artificial log 110 is shown. The
artificial log 110 includes a molded portion 112 that forms the
body of the article. Typically, the molded portion includes an
inorganic ceramic fiber and a binder. The molded portion 112
includes an outer surface 114 to which a particulate 116, such as
non-exfoliated vermiculite, is coupled. Particulate 116 is made of
a material that provides an incandescent glow or intensity when
heated or upon interaction with a flame. Particulates other than
non-exfoliated vermiculite can be coupled to the molded log such as
exfoliated vermiculite, mineral or rock wool, platinum embers, or
other incandescent materials suitable for gas fireplaces. Any
particulate that provides a differential effect or incandescent
intensity on the article can be utilized. Volatile metallic salts
can optionally be used in connection with the particulate for color
enhancement. One method of using volatile metallic salts is
described in U.S. Pat. No. 5,429,495, which is incorporated by
reference herein.
[0026] During heating or the interaction with a flame, the
particulate 116 provides an effect different from the effect
created by heating the molded portion 112. For example, as the
particulate 116, such as non-exfoliated vermiculite, is heated it
can expand and glow similar to the burning that is observed on a
natural burning log. This forms an expanded or altered particulate
117. After expanding from heating, the expanded particulate 117 can
fall to the bottom of a combustion chamber enclosure or onto a gas
burner and continue to glow similar to embers and/or ash seen on
the floor of a natural fireplace or remain attached to log. One
example of an expanded particulate is exfoliated vermiculite. The
expanded particulate 117 that remains coupled to molded portion 112
can continue to glow in a differential way than the molded portion
112. Other particulates that may not expand upon heating, such as
mineral wool, can be utilized as a particulate 116 to create an
incandescent intensity or effect that is different from the molded
portion 112.
[0027] Molded portion 112 can be formed from, for example,
inorganic ceramic fibers and a binder. Molded portion 112 can be
formed by any known molding technique, such as, for example,
compression molding and vacuum forming techniques. Exemplary
compression molding compositions and forming techniques are
described in pending U.S. patent application Ser. No. 09/781,148,
which is incorporated herein by reference. Additional exemplary
molding compositions and forming techniques are described in U.S.
Pat. Nos. 5,941,237; 5,996,575; and 6,170,481; which are
incorporated herein by reference.
[0028] In one embodiment of forming a gas fireplace article, such
as artificial log 110, the particulate 116 can be coupled to outer
surface 114 with a high temperature adhesive such as a ceramic
adhesive 118. The particulate 116 can be placed on the surface in
positions that provide a realistic glowing log. For example,
non-exfoliated vermiculite can be concentrated on a front bottom
portion 119 of the artificial log 110 to provide a more significant
glow in this region of the artificial log 110.
[0029] Non-exfoliated vermiculite, also know as crude vermiculite
or vermiculite concentrate, typically increases in volume about 6
to 12 times when heated to form exfoliated vermiculite (expanded
vermiculite). Some individual flakes of non-exfoliated vermiculite
can expand as much as 30 times in volume. During the conversion
from non-exfoliated vermiculite (expandable particulate) to
exfoliated vermiculite, the color of the vermiculite can change.
This change can vary based upon the temperature in a particular
location or flame position relative to the vermiculite particle.
Another example of an expandable particulate is mica.
[0030] Particulate 116 can be adhered to the outer surface 114 of
the artificial log 110 prior to the sale of the article to a
consumer. Alternatively, the particulate can be sold as a kit with
the ceramic adhesive so that the consumer can apply the
particulate: as desired to a molded log; to previously purchased
compression molded or vacuum formed logs; or to replace spent
particulate that has been previously heated and fallen off a molded
log.
[0031] Referring to FIG. 3, a cross-sectional view of a second
embodiment of an artificial log 210 is shown. The artificial log
210 includes a distribution of particulate 216 throughout molded
portion 212.
[0032] In the embodiment of FIG. 3, the particulate 216 can be
coupled to the molded portion 212 through incorporation into a
molding composition that is processed to form a gas fireplace
article 200, such as artificial log 210. Incorporation of the
particulate 116 into the molding composition will create a
particulate distribution in the finished article. For example, a
non-exfoliated vermiculite material can be incorporated into a
slurry of inorganic ceramic fiber and a binder. The slurry is then
utilized in a vacuum molding technique to form the article 200.
Alternatively, the particulate can be incorporated into a
compression molding composition. In another embodiment, the molding
composition that includes the particulate can be applied to the
surface of an existing article.
[0033] After the molding process, the non-exfoliated vermiculite
(particulate 116) is thereby dispersed within the finished article
200. At least some of the particulate 216 is exposed on the outer
surface 214 of the artificial log 210 to provide an effect
different than the effect created from the inorganic ceramic fiber
and binder that was included in the slurry.
[0034] Referring to FIGS. 4 and 5, some compression molded articles
include particulate 316, for example, a non-exfoliated vermiculite,
that burns and falls from the log exposing an inner portion 320 of
the molded portion to heat or a flame. Due to differences in the
density and composition of the molded portion 312, this inner
portion 320 typically glows differently from the ceramic fiber and
binder that forms the outer surface 314 of the molded portion 312.
For example, as shown in FIGS. 4 and 5, the inner portion 320 is
less dense than an outer portion 321 of the article 300. This
creates yet another differential glowing effect that is viewable by
the consumer.
[0035] Referring to FIG. 6, a cross-sectional view of a third
embodiment of an article 400 shaped as artificial log 410, is
shown. The artificial log 410 includes particulate 416 that is
coupled to log through the creation of recess 422, such as a
pocket, pit, or hole. The recess 422 is defined by the outer
surface 414 of the artificial log 410. For example, pieces of
particulate 424, such as non-exfoliated vermiculite, can be
inserted within pits in an outer surface 414 of the artificial log
410.
[0036] In another application, an insert 426 can be formed to fit
within a recess 428. The insert 426 can include a particulate 416
such as non-exfoliated vermiculite coupled to a molded material
429, such as a ceramic fiber and a binder.
[0037] As materials such as particulate 416 and/or particulate 424
are expended during use of the fireplace, either the insert and/or
pieces of material can be replaced with knew material or inserts
that are the same or different from the material originally used to
fill the recess. Alternatively, a paste or slurry of molding
composition that includes the particulate can be applied to fill a
recess on a gas fireplace article.
[0038] The pits, pockets, or holes can be formed during the
compression or vacuum molding process or formed through
post-article forming manufacturing processes, such as, for example,
drilling, etching, sawing, or other processes. For compression
molded articles to which a portion of the article is removed
through a post-compression manufacturing process, as a particulate,
such as, for example, non-exfoliated vermiculite burns and falls
from the log, an inner portion of the compression molded ceramic
fiber and binder is then exposed to heat or the flame. Due to
differences in the density and composition of the compression
molded ceramic fiber and binder, this inner portion typically glows
differently from the ceramic fiber and binder that forms the outer
surface of the molded portion, creating an additional differential
glowing effect.
[0039] Referring to FIG. 7, a cross-sectional view of an embodiment
of an article 500 in the form of a burner 510 is shown. A pan
portion 511 is coupled to a molded portion 512. A gas tube 513
supplies a gas/air mixture to a space 515 defined by the molded
portion 512 and the pan portion 511. The gas/air mixture travels
from space 515 through ports 521 that are defined by the molded
portion 512. The gas/air mixture then passes out of port 521 for
combustion.
[0040] Burner 510 includes a particulate 516. Similar to artificial
log 110, burner 510 includes the particulate 516 coupled to an
outer surface 514 of a molded portion 512 with an adhesive 518. The
particulate 516 can be incorporated into burner 510 through
adhesion or any of the other methods described for the formation of
artificial log 110.
[0041] Referring to FIG. 8, a cross-sectional view of a second
embodiment of a burner 610 is shown. Burner 610 is similar to
burner 510 in that it includes a pan portion 611, a molded portion
612, a gas tube 613, a space 615, and ports 621. Particulate 616
can be incorporated into the molded portion 612 of burner 610
similar to as described for artificial log 210.
[0042] Referring to FIG. 9, a cross-sectional view of a third
embodiment of a burner 710 is shown. Burner 710 is similar to
burner 510 in that it includes a pan portion 711, a molded portion
712, a gas tube 713, a space 715, and ports 721. Particulate 716
can be incorporated into the molded portion 712 of burner 710
similar to as described for artificial log 410.
[0043] In another embodiment of a method for forming a gas
fireplace article, such as an artificial log, a vacuum forming
technique is utilized. For example, a non-exfoliated vermiculite
can be combined with water and alumina silicate to form a
particulate slurry. The particulate slurry is drawn with a vacuum
through a screen leaving the non-exfoliated material deposited on
the screen. A second slurry of ceramic fibers and binder is then
introduce to the mold and drawn through the screen leaving the
ceramic fibers and binder deposited upon the non-exfoliated
vermiculite. With this method, the non-exfoliated vermiculite
remains exposed on the outer surface of the finished article.
[0044] Optionally, organic wood particles can be incorporated into
the ceramic fiber and binder articles. The organic wood particles
can generate smoke and burn away to further simulate the realism of
a natural fire.
[0045] The present invention should not be considered limited to
the particular examples described above, or to the materials used
to describe the various embodiments, but rather should be
understood to cover all aspects of the invention as broadly set out
in the attached claims. Various modifications, equivalent
processes, as well as numerous structures to which the present
invention may be applicable will be readily apparent to those of
skill in the art to which the present invention is directed upon
review of the instant specification.
* * * * *