U.S. patent application number 10/656853 was filed with the patent office on 2005-03-10 for fireplace surround.
Invention is credited to Hanel, Jeffrey Paul, Johnson, Timothy Wayne, Lyons, David Charles, Schroeder, Ted Victor.
Application Number | 20050050805 10/656853 |
Document ID | / |
Family ID | 34226448 |
Filed Date | 2005-03-10 |
United States Patent
Application |
20050050805 |
Kind Code |
A1 |
Lyons, David Charles ; et
al. |
March 10, 2005 |
Fireplace surround
Abstract
The invention generally relates to a fireplace surround for
attachment to a fireplace. The surround may include first and
second side members formed from a molded material, and a top member
formed from the molded material that extends between the first and
second side members. The top member defines a cavity that is in
fluid communication with a vent of the fireplace to collect heated
air from the fireplace. An opening formed in the top member
facilitates movement of heated air collected in the cavity to pass
through the cavity. The surround may also include a shield member
that direct the heated air from the fireplace vent to the exhaust
opening in the top member, and an insulating member that dissipates
heat in the top member.
Inventors: |
Lyons, David Charles; (Red
Wing, MN) ; Schroeder, Ted Victor; (Welch, MN)
; Johnson, Timothy Wayne; (Janesville, MN) ;
Hanel, Jeffrey Paul; (Savage, MN) |
Correspondence
Address: |
MERCHANT & GOULD PC
P.O. BOX 2903
MINNEAPOLIS
MN
55402-0903
US
|
Family ID: |
34226448 |
Appl. No.: |
10/656853 |
Filed: |
September 4, 2003 |
Current U.S.
Class: |
52/36.3 |
Current CPC
Class: |
E04F 19/00 20130101;
F24B 1/1808 20130101; F23N 5/203 20130101; F24B 1/198 20130101 |
Class at
Publication: |
052/036.3 |
International
Class: |
E04F 019/00 |
Claims
We claim:
1. A surround for attachment to a fireplace, comprising: first and
second side members formed from a molded material; a top member
formed from the molded material and extending between the first and
second side members, the top member defining a cavity that is in
fluid communication with a vent of the fireplace to collect heated
air from the fireplace; and an opening defined by the top member,
the opening configured to exhaust the collected air from the
cavity.
2. The surround of claim 1, wherein the first and second side
members extend in a substantially vertical direction.
3. The surround of claim 1, wherein the top member extends in a
substantially horizontal direction.
4. The surround of claim 1, further comprising a lower member
extending between the first and second side members at a position
vertically below the top member.
5. The surround of claim 4, wherein the first and second side
members and the top member are constructed as a single, monolithic
piece.
6. The surround of claim 5, further comprising an access panel
secured to the surround at a position vertically below the lower
member.
7. The surround of claim 6, wherein the access panel is removably
secured to the surround by at least one fastener.
8. The surround of claim 1, wherein the opening defined by the top
member includes at least two distinct openings.
9. The surround of claim 1, further comprising an insulating member
configured to fit within a portion of the cavity.
10. The surround of claim 1, further comprising a connector
configured to secure the surround to the fireplace.
11. The surround of claim 1, wherein the molded material includes a
ceramic fiber and a binder.
12. A fireplace, comprising: a heat source configured to generate
heated air; a vent for exhausting the heated air outside the
fireplace; and a fireplace surround, the surround including: first
and second side members formed from a molded material; a top member
formed from the molded material and extending between the first and
second side members, the top member defining a cavity that is in
fluid communication with the heated air exhausted from the vent;
and an opening defined by the top member, the opening configured to
exhaust the heated air from the cavity.
13. The surround of claim 12, further comprising an insulating
member configured to fit within a portion of the cavity.
14. The surround of claim 12, further comprising a shield member
configured to direct heated air exhausted from the vent through the
cavity.
15. The surround of claim 14, wherein the top member is positioned
vertically above the combustion chamber.
16. The surround of claim 1, wherein the molded material includes a
ceramic fiber and a binder.
17. A fireplace surround, comprising: a molded first member having
first and second sides and an opening extending between the first
and second sides; wherein the first side is configured to be
positioned adjacent to a vent of the fireplace so that heated air
exhausted from the fireplace vent moves through the opening.
18. The surround of claim 17, further comprising an insulating
member positioned in the first member.
19. The surround of claim 17, wherein the first member is molded
from a material that includes a ceramic fiber and a binder.
20. The surround of claim 17, further comprising a cavity formed in
the first member between the first and second sides, and the
opening provides access to the cavity.
21. The surround of claim 17, further comprising a shield member
configured to direct air through the opening.
22. A method of forming a fireplace surround for attachment to a
fireplace, the method comprising the steps of: forming a first
member from a molded material, the first member being configured
for positioning adjacent to a vent of the fireplace; and forming an
opening in the first member that extend through the first member;
wherein heated air exhausted from the fireplace vent moves through
the opening in the first member.
23. The method of claim 22, further comprising the step of forming
a cavity within the first member, wherein the opening provides
access to the cavity.
24. The method of claim 22, further comprising the step of forming
first and second side members from the molded material and
orienting the first and second side members along vertical sides of
the fireplace.
25. The method of claim 22, further comprising the step of forming
a lower member and orienting the lower member horizontally across a
lower portion of the fireplace.
26. The method of claim 22, further comprising the step of
orienting the first member horizontally across an upper portion of
the fireplace.
27. The method of claim 25, further comprising the step of forming
an access panel configured for attachment to the surround at a
location below the lower member.
28. The method of claim 27, further comprising the step of
releasably securing the access panel to the surround with a
fastener.
29. The method of claim 22, wherein the step of forming an opening
includes forming at least two openings in the first member that
each extend through the first member.
30. The method of claim 23, wherein the surround further comprises
an insulating member and the method further comprises the step of
positioning the insulation member in the cavity.
31. The surround of claim 22, wherein the step of forming the first
member includes compression molding the first member from a molded
material that includes a ceramic fiber and a binder.
32. The surround of claim 22, wherein the step of forming the first
member includes vacuum molding the first member from a molded
material that includes a ceramic fiber and a binder.
33. A fireplace venting assembly, comprising: a return air plenum;
and a surround aligned with an opening of the plenum and including
a surround opening that extends through the surround to vent air
from the plenum opening through the surround.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention generally relates to fireplaces, and
more particularly relates to a fireplace surround for a
fireplace.
[0003] 2. Related Art
[0004] Fireplaces have become increasingly commonplace in homes,
businesses, and other buildings. A fireplace provides benefits
including the generation of heat as well as an aesthetically
pleasing arrangement of flames, sounds, and smells. A fireplace is
typically mounted in or adjacent to a wall and may include one or
more exposed surfaces.
[0005] The fireplace box that defines the combustion chamber may
assume a number of different configurations. In traditional wood
burning fireplaces of brick and mortar construction, the combustion
chamber generally extends over the full height of the. fireplace
box, and a log-holding grate rests on the floor of the combustion
chamber. For gas burning fireplaces, the burner assembly and
associated gas supply mechanisms are typically located below the
floor of the combustion chamber but often still within the open
cavity defined by the fireplace box. A number of fireplaces also
include a heating plenum surrounding the fireplace box. Typically,
room air is drawn into the plenum near the bottom of the fireplace
box, the air is heated as it travels around the fireplace box
within the plenum, and the heated air is emitted back into the room
near the top of the fireplace box.
[0006] In order to provide an aesthetically pleasing design for the
exposed fireplace front, most fireplaces include wide metal panels
near the top and bottom portions of the open front fireplace box to
cover or mask the mechanisms and openings that are otherwise
visible. Such panels may be coated with brass, bronze or anodized
metal finishes for improved aesthetics. The vertical area between
the upper and lower decorative metal panels generally contains one
or more panels of glass that form a seal with the front of the
fireplace box or include at least one operable door panel that
provides access to the combustion chamber.
[0007] Metal panels typically used for fireplace surrounds conduct
heat and may become unsafe to touch. Thus, it is desired to provide
a fireplace surround surface that has reduced heat conduction
properties as compared to a metal surface. Also, although the metal
panels cover up unsightly parts of the fireplace, the metal panels
themselves may have poor aesthetics. Areas surrounding many
fireplaces often include stone, brick or other natural materials or
natural-appearing materials. For example, a hearth of the fireplace
may be made of stone, brick, or the like. Therefore, the metal
panel may contrast unattractively with the natural material
surrounding the fireplace or the fireplace hearth. Moreover, it
would be expensive to create a top or bottom panel out of stone or
brick, and these materials generally prove difficult to shape and
size. Also, the mounting of such material may be difficult due to
the heavy weight of those materials.
[0008] Thus, it would be desirable from both aesthetic and cost
viewpoints to provide for a fireplace surround that improves the
appearance of a pre-existing or new fireplace while addressing at
least those shortcomings of known fireplaces and fireplace
surrounds noted above.
SUMMARY
[0009] The present invention generally relates to fireplaces and
more particularly relates to fireplace surrounds. One aspect of the
invention relates to a fireplace surround for attachment to a
fireplace. The surround includes first and second side members
formed from a molded material, and a top member formed from the
molded material that extends between the first and second side
members. The top member defines a cavity that is in fluid
communication with a vent of the fireplace to collect heated air
from the fireplace. The top member also includes an opening that
exhausts heated air from the cavity.
[0010] Another aspect of the invention relates to a fireplace that
includes a heat source configured to generate heated air, a vent
for exhausting the heated air outside the fireplace, and a
fireplace surround. The surround includes first and second side
members formed from a molded material, and a top member formed from
the molded material that extends between the first and second side
members. The top member defines a cavity that is in fluid
communication with the heated air exhausted from the vent, and
further defines an opening configured to exhaust the heated air
from the cavity.
[0011] A yet further aspect of the invention relates to a fireplace
surround that includes a molded first member having first and
second sides and an internal cavity defined by the first and second
sides. The first side of the surround is open to provide a first
access to the cavity, and the second side is defined by a sidewall
that includes an aperture providing a second access to the cavity.
The first side is configured for mounting to the fireplace adjacent
a fireplace vent so that air heated by the fireplace passes through
the first access into the cavity. The heated air may then pass out
from the cavity through the second access.
[0012] A further aspect of the invention relates to a method of
forming a fireplace surround for attachment to a fireplace. The
method includes forming a first member from a molded material,
wherein the first member defines a cavity and is configured for
mounting to the fireplace adjacent a vent of the fireplace. The
method also includes forming an opening in the first member that
provides access to the cavity so that heated air from the fireplace
may pass through the vent into the cavity and pass out from the
cavity through the opening.
[0013] Yet another aspect of the invention relates to a fireplace
venting assembly that includes a return air plenum and a surround
aligned with an opening of the plenum. The surround includes a
surround opening that extends through the surround to vent air from
the plenum opening through the surround.
[0014] The above summary of the present invention is not intended
to describe each disclosed embodiment or every implementation of
the present invention. Figures in the detailed description that
follow more particularly exemplify embodiments of the invention.
While certain embodiments will be illustrated and described, the
invention is not limited to use in such embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] 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:
[0016] FIG. 1 is a perspective view of one example fireplace
surround assembly according to principles of the invention spaced
apart from a fireplace unit;
[0017] FIG. 2 is a cross-sectional side view of the surround
assembly and fireplace unit shown in FIG. 1 taken along
cross-sectional indicators 2-2;
[0018] FIG. 3 is a front view of the fireplace surround assembly
shown in FIG. 1;
[0019] FIG. 4 is an exploded perspective view of the fireplace
surround assembly shown in FIG. 1;
[0020] FIG. 5 is a close up view of the cross-sectional view of the
surround top member shown in FIG. 2;
[0021] FIG. 6 is a rear view of the fireplace surround assembly
shown in FIG. 1;
[0022] FIG. 7 is a top view of the fireplace surround assembly
shown in FIG. 1;
[0023] FIG. 8 is a side view of the fireplace surround assembly
shown in FIG. 1;
[0024] FIG. 9 is an exploded rear perspective view of an access
panel that may be added to the fireplace surround assembly shown in
FIG. 1;
[0025] FIG. 10 is a front view of the access panel shown in FIG. 9;
and
[0026] FIG. 11 is a front view of the fireplace surround assembly
of FIG. 1 including the access panel shown in FIG. 9.
[0027] While the invention is amenable to various modifications and
alternant forms, specifics thereof have been shown by way of
example and 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 falling within the spirit and scope of the
invention.
DETAILED DESCRIPTION
[0028] The present invention generally relates to fireplaces and
more particularly relates to fireplace surrounds. In many fireplace
applications, it is desirable to cover the metal top, bottom and
side panels of a fireplace, the gap that typically exists between
the fireplace and the finished wall surface around the fireplace,
and the vents and access openings and controls of the fireplace. In
many applications, a fireplace surround or surround assembly as
well as a fireplace front must be used to provide the desired
aesthetic affect. Further, it may be desirable to use covering
materials for the surround that have a natural appearance that
blends with the fireplace hearth and other features around the
fireplace, and to use covering materials that are low-cost and
relatively easy to form into desired shapes. Moreover, it is often
desirable for a fireplace surround to have low heat conductive
properties to improve safety of the fireplace. The following
example fireplace surrounds address these and other objectives and
provide an improvement over known fireplace surrounds. While the
present invention is not so limited, an appreciation of the various
aspects of the invention will be gained through a discussion of the
examples provided below.
[0029] As used herein, the term "surround" means any exposed
structural surface that covers at least a portion of the front
surface of a fireplace and provides a transition from the
combustible material surrounding the fireplace (such as, for
example, a sheetrock wall) to the sheet metal of the fireplace
front. The "surround" may function as a door or similar structure
that provides access to otherwise covered features of the
fireplace. The "surround" may also function as a fireplace front
that covers portions of the fireplace, for example, the fireplace
viewing surface (e.g., glass), frame or louvers. Thus, a surround
according to principles of the invention may be advantageous for
combining several functions of previously required pieces (i.e.,
door, surround, and front) into a single unit, thereby saving cost
for the consumer while providing an aesthetically pleasing
solution.
[0030] The phrase "viewing surface" is any surface through which at
least a portion of an interior of a fireplace may be viewed. For
example, a viewing surface may consist of a pane of translucent
tempered or ceramic glass or high-temperature plastic positioned to
cover at least a portion of an opening of a fireplace. The phrase
"combustion chamber enclosure" may include any enclosure in which
flames and/or heat are generated or simulated. The term "fastener"
includes, for example, magnets, clamps, brackets, bolts, screws,
and similar structures that secure together two or more
members.
[0031] An example fireplace 50 illustrated in FIGS. 1 and 2
includes an outer enclosure 60, a viewing surface 70, upper and
lower grills 80, 90, upper and lower vents 85, 95, a combustion
chamber enclosure 62, and a combustion chamber 64. A burner 66
positioned in the combustion chamber enclosure combusts gas and
thereby generates heat. The burner is typically coupled by a gas
line to a source of combustible gas. These features are standard on
gas fireplaces and, therefore, are not identified in the drawings.
A suitable example fireplace for use with a surround disclosed
herein is described and illustrated in U.S. Patent Application
Publication No. 2003/0089365, which is incorporated herein by
reference in its entirety.
[0032] Fireplace 50 may be any type of fireplace, such as, for
example, a solid-fuel, gas, or electric fireplace. In the example
embodiment, the fireplace 50 is a gas fireplace. Fireplace 50 is
provided as an example only, and any other known configuration for
a fireplace may also be used. For example, the present invention
may be used in conjunction with any prefabricated gas fireplace
such as, for example, a direct vent, a universal vent, a B-vent, a
horizontal/vertical-vent, a dual direct vent, or any fireplace unit
to which the present fireplace surround may be fitted. Further, the
invention may be utilized in any configuration of a solid-fuel
burning or electric fireplace as well.
[0033] Lower vent 85 acts as a room air intake that draws
relatively cool room air (in the direction A) into a plenum 75
(portions of which are shown in FIG. 2) that surrounds the
combustion chamber enclosure 62 and provides fluid communication
between the top and bottom vents 85, 95. As the cool air drawn in
through lower vent 85 moves around the combustion chamber enclosure
62, heat emanating from combustion chamber 64 heats the air. The
heated air rises naturally in the plenum, or is moved through the
plenum with a blower (not shown), towards upper vent 85. The heated
air then exits upper vent 85 (in the direction B), which vent
serves as an exhaust for the heated air.
[0034] A fireplace surround assembly 100 shown in FIGS. 1-8 may be
mounted or positioned adjacent to outer enclosure 60 of fireplace
50. Surround assembly 100 includes a top member 102 that extends in
a generally horizontal direction between two vertically oriented
side members 104, 106. In addition, surround assembly 100 includes
a lower horizontal member 108, although this feature may not be
included in some embodiments. Side members 104, 106 and top and
lower members 102, 108 may be integrally formed together as a
single piece or may be formed as separate pieces or groups of
pieces that are then assembled together using, for example,
fasteners, adhesives, or some other assembly means. The horizontal
direction referred to herein is with respect to a horizontal plane,
such as a plane associated with a floor surface on which the
surround and fireplace rest, and a vertical plane is orientated in
a direction perpendicular to the horizontal plane.
[0035] Surround assembly 100 may be constructed of molded
materials, for example, a molded material that includes an
inorganic ceramic fiber and a binder. The molded materials may be
formed by any known molding technique, such as, for example,
compression molding or vacuum forming techniques. Exemplary
compression molding compositions and forming techniques are
described in pending United States Patent Application Publication
No. 2003/0049575, which is incorporated herein by reference in its
entirety. 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 also incorporated herein by reference in
their entirety.
[0036] The use of molded materials provides potential design and
functional advantages for a surround. For example, the various
brackets described herein may be directly molded into the surround
rather than being separately secured to the surround with a
fastener or the like attachment means. Further options may include
directly molding wiring, switches, lighting, and various control
features into the molded portion of the surround.
[0037] The exact shaping of the fireplace surround 100 may be
entirely formed during the compression or vacuum molding process or
it may be formed through post-article forming manufacturing
processes, such as, for example, drilling, etching, sawing,
milling, or other processes. The compression or vacuum molded
materials may be formed and colored so as to have the appearance of
stone, brick, or any other natural material that may be desired.
Molding processes may be particularly useful for creating surrounds
with complicated features that would otherwise be difficult to
create if using other methods, such as stamping. For example, a top
member formed using a molding process may include a contoured
exterior surface, an inner cavity with planar or contoured
surfaces, and an aperture formed between the exterior surface and
cavity, which features may all be formed in a single step of
forming the top member.
[0038] Top member 102 may include front and rear facing sides 111,
113, wherein front facing side 111 is defined by a sidewall 115
that defines a cavity 105, and rear facing side 113 is open. In
other embodiments, rear facing side 113 may be partially closed
with a sidewall and include apertures aligned with vent 95 to
permit the flow of air into cavity 105.
[0039] Top member 102 may include one or more apertures 103 formed
in sidewall 115 that provide fluid communication between cavity 105
and air on the outside of sidewall 115. The number and orientation
of apertures 103 may depend on the configuration of grill 90 and
vents 95. The generally downward facing orientation of apertures
103 shown in FIG. 4 may be desired for directing heat into a room
area at a downward angle, although other embodiments may include
additional or replacement apertures oriented in different
directions.
[0040] Surround assembly 100 may also include a shield member 130
and an insulating member 160 that are mounted to top member 102
within cavity 105, as shown in FIGS. 4-6. Brackets 110, 120 may be
used to secure insulating and shield members 160, 130 to top member
102 (see FIG. 6). As shown in FIGS. 7 and 8, the shield and
insulating members 130, 160 are mounted within top member 102 (see
side and top profiles of assembly 100 shown in FIGS. 7 and 8) that
top member 102 can be flush mounted against outer enclosure 60 of
fireplace 50.
[0041] When surround assembly 100 is mounted or positioned adjacent
to outer enclosure 60 of fireplace 50, rear facing side 113 is
aligned with vent 95 so that heated air exhausted from vent 95
passes into cavity 105. Shield member 130 is positioned relative to
vent 85 so that the air from vent 95 is directed at an angle toward
aperture 107 along a path represented by arrows 109. Because the
air being exhausted through vent 95 is typically heated, contact by
this air against shield member 130 may cause the shield member to
become very hot. In other embodiments that do not include a shield
member, the heated air may contact sidewall 115 resulting in the
entire surround to become very hot. In order to prevent sidewall
115 from becoming heated to the point that it may be a safety
hazard, insulating member 160 is positioned so as to be between
vent 95 and sidewall 115 to absorb and dissipate heat. In the
embodiment illustrated in FIGS. 4 and 6, insulating member 160 is
positioned between shield member 130 and sidewall 115.
[0042] Surround assembly 100 preferably rests flat on a floor
surface in front of the fireplace 50. In this manner the floor
primarily supports the weight of surround assembly 100.
Alternatively, the surround 100 may be attached to fireplace 50
without being supported by the floor.
[0043] Surround assembly 100 may be attached to the existing
fireplace 50 by left and right side pawl assemblies (connectors)
140, 150. Each pawl assembly 140, 150 is connected to the back of
the surround assembly 100 (see FIG. 6), and may be adjusted into a
surface of fireplace 50. Alternatively, surround assembly 100 may
be connected to fireplace 50 by any appropriate mechanical means,
such as using bolts, screws, adhesive, or the like securing
methods. Surround assembly 100 may, in some embodiments, be a
freestanding unit that is placed in front of fireplace 50 without
any means of connection to fireplace 50.
[0044] As shown in the figures, the edges of surround assembly 100
are contoured to improve aesthetics and to remove any sharp edges
that could cause injury. However, other shapes or configurations,
such as a rectangular shape or any other multi-faceted shape, are
contemplated by the present invention.
[0045] Surround assembly 100 may further include an access panel
170 that extends along a bottom portion of fireplace 50, for
example, between first and second side members 104, 106 below lower
member 108. Access panel 170 may be attached to first and second
side members 104, 106 with brackets 172, 174. Brackets 174 may be
magnets, snap-fit structures, or other quick release fastening
structures that may be secured to brackets 172 (such as with a
fastener 176). The quick release nature of access panel 170 may
provide easy access to certain features of fireplace 50, such as
controls for a gas burner, a blower or other mechanisms of the
fireplace. If no access to fireplace 50 is needed or desired, or if
the need for access is limited, access panel 170 may be permanently
attached to surround 100 by screws or the like.
[0046] Access panel 170 may be positioned so as to provide a gap
(see FIG. 11) between the lower horizontal member 108 and the
access panel 170 to allow intake air to flow freely into vent 85 of
fireplace 50. However, this gap does not have to be present nor
does the gap have to be as large as shown in FIG. 11.
Alternatively, the gap may also be positioned below access panel
170.
[0047] In the examples described above, the exhaust vent 95 is
positioned at an upper portion of fireplace 50, which position may
be advantageous for some fireplace designs. However, in other
embodiments, the exhaust vents may be located at other locations
around the fireplace, such as along vertical sides or across the
bottom of the fireplace. In such alternative embodiments, a portion
of the surround assembly equivalent to top member 102 that
includes, for example, a cavity, apertures, shields and insulation
may be aligned with the fireplace exhaust vent so as to provide the
advantages and functions of the examples described above.
[0048] In another aspect of the invention, a surround is provided
for use with a return air plenum, for example the fireplace plenum
discussed above. The surround includes an opening that extends
through the surround so that air exhausted from an opening of the
plenum vents through the surround opening.
[0049] The present invention should not be considered limited to
the particular examples or materials described above, but rather
should be understood to cover all aspect of the invention as fairly
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.
* * * * *