U.S. patent application number 10/893159 was filed with the patent office on 2005-04-14 for compression molded trimmable surround.
This patent application is currently assigned to HNI Technologies Inc.. Invention is credited to Hanel, Jeffrey Paul, Lyons, David Charles, Weir, Todd Robert.
Application Number | 20050076902 10/893159 |
Document ID | / |
Family ID | 34426350 |
Filed Date | 2005-04-14 |
United States Patent
Application |
20050076902 |
Kind Code |
A1 |
Lyons, David Charles ; et
al. |
April 14, 2005 |
Compression molded trimmable surround
Abstract
A trimmable surround and methods for creating the surround for a
heat generating device. The trimmable surround includes a molded
portion having a ceramic fiber and a binder and an attachment
portion. A portion of the molded member is removable to alter a
size of the molded member. An attachment portion coupled to the
molded portion allows attachment of the trimmable surround to the
heat generating device.
Inventors: |
Lyons, David Charles; (Red
Wing, MN) ; Weir, Todd Robert; (Edina, MN) ;
Hanel, Jeffrey Paul; (Savage, MN) |
Correspondence
Address: |
Merchant & Gould P.C.
P.O. Box 2903
Minneapolis
MN
55402-0903
US
|
Assignee: |
HNI Technologies Inc.
Muscatine
IA
52761-7109
|
Family ID: |
34426350 |
Appl. No.: |
10/893159 |
Filed: |
July 15, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60574821 |
Jul 15, 2003 |
|
|
|
Current U.S.
Class: |
126/500 |
Current CPC
Class: |
F24B 1/18 20130101; F24B
1/198 20130101 |
Class at
Publication: |
126/500 |
International
Class: |
F24B 001/18; F24B
001/188; F24B 001/189 |
Claims
What is claimed is:
1. A trimmable surround for a heat generating device, the trimmable
surround comprising: a molded member comprising a ceramic fiber and
a binder, a portion of the molded member being removable to alter a
size of the molded member; and an attachment member coupled to the
molded member and configured to couple the trimmable surround
adjacent to an exposed panel of the heat generating device.
2. The trimmable surround of claim 1, wherein the attachment member
comprises a top bracket, the top bracket defining a slot configured
to receive a mounting tab of the heat generating device.
3. The trimmable surround of claim 1, wherein the heat generating
device is a fireplace insert.
4. The trimmable surround of claim 1, wherein the molded member
comprises a top member and opposing side members.
5. The trimmable surround of claim 1, wherein the size of the
molded member to be altered is a height or a width of the surround
outer circumference.
6. The trimmable surround of claim 1, wherein the size of the
molded member to be altered is a height or a width of an inner
opening sized to cover at least a portion of the exposed panel.
7. The trimmable surround of claim 1, wherein the molded member
comprises an outer surface configured for forming a decorative
design.
8. The trimmable surround of claim 1, wherein the molded member is
formed by compression molding.
9. A gas fireplace comprising: a front panel including an exposed
portion; a surround positioned adjacent to the front panel, the
surround comprising: a molded member comprising a ceramic fiber and
a binder, a portion of the molded member being removable to alter a
size of the molded member; and an attachment member coupled to the
molded member, the attachment member being configured to secure the
surround adjacent to the front panel; wherein the front panel is
positioned to cover at least a portion of the exposed surface of
the front panel.
10. The fireplace of claim 9, wherein the attachment member is
configured to secure the surround to the front panel.
11. The fireplace of claim 9, wherein the molded member defines an
opening, and a portion of the molded member adjacent the opening
covers at least a portion of the exposed portion of the front
panel.
12. The fireplace of claim 11, wherein the portion of the molded
member that is removable alters a size of the opening of the molded
member.
13. The fireplace of claim 9, wherein the size of the molded member
to be altered is a height or a width of the surround outer
circumference.
14. A method of sizing a surround for a heat generating device, the
method comprising the steps of: providing a trimmable surround
sized greater than an opening defined by the heat generating
device, the trimmable surround comprising: a molded portion, the
molded portion comprising a ceramic fiber and a binder; and an
attachment portion coupled to the molded portion, the attachment
portion being configured to attach the trimmable surround in a
position in front of an exposed panel of the heat generating
device; measuring a size of the heat generating device opening; and
removing a portion of the trimmable surround based on the measured
size of the heat generating device opening.
15. The method of claim 14, further comprising the step of
attaching the trimmable surround to the heat generating device.
16. The method of claim 14, further comprising the step of
preparing a template based upon the measured size of the heat
generating device opening.
17. The method of claim 16, further comprising the step of placing
the template on the trimmable surround, wherein the step of
removing a portion of the trimmable surround includes sizing a
dimension of the surround to approximate a dimension of the
template.
18. The method of claim 14, wherein removing a portion of the
trimmable surround alters an outer circumference dimension of the
surround.
19. The method of claim 14, wherein removing a portion of the
trimmable surround alters a size of an opening defined by the
molded portion, the opening having dimensions that approximate the
measured size of the heat generating device opening.
20. The method of claim 14, wherein the step of removing a portion
of the trimmable surround includes cutting the molded portion.
21. The method of claim 14, further comprising forming the molded
member by compression molding.
22. The method of claim 14, further comprising forming the molded
member by vacuum molding.
23. The method of claim 14, further comprising forming the molded
member by casting.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional patent
application Ser. No. 10/620,297 filed on Jul. 15, 2003 and entitled
TRIMMABLE SURROUND FOR A HEAT GENERATING DEVICE, which provisional
application is incorporated herein by reference in its
entirety.
TECHNICAL FIELD
[0002] The present invention relates to heat generating devices.
More particularly, the invention relates to a trimmable surround
and a method for creating a modifyable surround for heat generating
devices.
BACKGROUND
[0003] Fireplaces and other heat generating devices have become
increasingly commonplace in homes, businesses, and other buildings.
For example, 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 a wall of a
structure and may include one or more exposed surfaces.
[0004] The exposed surfaces of the fireplace can pose safety
issues. For example, because the fireplace produces heat, it is
possible for one or more of the exposed surfaces of the fireplace
to become heated. In particular, metallic exposed surfaces can
become hot during fireplace use. Other surfaces of a fireplace that
are typically exposed are surfaces through which the interior of
the fireplace is viewed (e.g., a glass panel, door, or mesh screen)
and the surround that surrounds the fireplace and provides a
transition between the exposed fireplace surfaces and the wall
structure.
[0005] The exposed surfaces of the surround may become hot and pose
a risk of burns to individuals or damage to objects that come into
contact with the surfaces. Current fireplace design fails to
adequately provide an apparatus or method to maintain the exposed
surfaces of the fireplace surround at a temperature that is safe.
Also, a metallic exposed surface of the fireplace may not be as
aesthetically pleasing to the consumer or blend into a room's
decor.
[0006] Further, surrounds are often required to cover gaps that may
exist between a combustion device, such as a fireplace insert, and
the existing structure of the building, such as a wall or masonry.
Current fireplace surrounds that are placed over the exposed
surfaces of the fireplace can require custom measurement, cutting,
and/or preparation by the seller or manufacturer of the surround,
are difficult to modify by the consumer after purchase, and, if
prepared with a finish prior to shipment to the consumer, may not
match the decor surrounding the fireplace once placed over the
exposed surface(s) of the fireplace unit.
SUMMARY
[0007] Generally, the present invention relates to heat generating
devices. More particularly, the invention relates to a trimmable
surround and a method for creating a modifyable surround for heat
generating devices.
[0008] According to one aspect, the invention relates to a
trimmable surround and methods for creating the surround for a heat
generating device. The trimmable surround includes a molded portion
having a ceramic fiber and a binder, and an attachment portion. The
attachment portion is coupled to the molded portion to allow
attachment of the trimmable surround to the heat generating device.
The trimmable surround may be reduced in size by, for example,
cutting or trimming portions of the surround.
[0009] 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
[0010] 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:
[0011] FIG. 1 is a front view of an example surround made in
accordance with the present invention;
[0012] FIG. 2 is a cross-sectional view taken along line 2-2 of the
surround shown in FIG. 1;
[0013] FIG. 3 is a front view of a second example surround made in
accordance with the present invention;
[0014] FIG. 4 is a back view of the surround shown in FIG. 3;
[0015] FIG. 5 is front/top exploded perspective view of the
surround shown in FIG. 3;
[0016] FIG. 6 is a front view of an example fireplace including an
example embodiment of a trimmable surround made in accordance with
the present invention;
[0017] FIG. 7 is a front/top perspective view of the fireplace and
trimmable surround shown in FIG. 6;
[0018] FIG. 8 is a top view of the fireplace and trimmable surround
shown in FIG. 6;
[0019] FIG. 8A is an enlarged view of a portion of the fireplace
and trimmable surround shown in FIG. 8;
[0020] FIG. 9 is a front/top exploded perspective view of the
fireplace and trimmable surround shown in FIG. 6;
[0021] FIG. 10 is a side view of the fireplace and trimmable
surround shown in FIG. 6 installed within an opening of a wall
structure; and
[0022] FIG. 10A is an enlarged view of a portion of the fireplace
and trimmable surround shown in FIG. 10.
[0023] While the invention is amenable to various modifications and
alternative 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
[0024] The present invention relates to fireplaces. More
particularly, the invention relates to a surround for a fireplace
that can be easily modified, installed over or adjacent to an
exposed surface of a fireplace, and finished as desired by the
consumer. 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.
[0025] Embodiments of the present invention may be used in
conjunction with any system or apparatus that ignites a combustible
gas to generate a gas flame or any other heat generating device. A
non-exhaustive list of such heat generating devices may include
fireplaces, grills, stoves, furnaces etc. Other embodiments of the
present invention may also be applicable to other heat generating
devices such as electric fireplaces, and be applicable to simulated
fire display devices. While the example embodiments of the present
invention provided below are described in conjunction with an
example fireplace insert, the present invention is equally
applicable to other systems or apparatuses besides a fireplace that
ignite a combustible gas to generate a gas flame or that simulate a
flame.
[0026] As used herein, the term "coupled" means any structure or
method that may be used to provide connectivity between two or more
elements, which may or may not include a direct physical connection
between the elements. The terms "exposed panel" and "exposed
surface" mean any panel or surface of the fireplace or other device
that may heated by heat generated by the fireplace and that is
accessible by the operator or user of the fireplace following
installation. The phrase "combustion chamber enclosure" may include
any enclosure in which flames and/or heat are generated or
simulated. The term "surround" means any exposed structural surface
that covers or is adjacent to a portion of the fireplace (e.g.,
"exposed surface") or structure adjacent thereto.
[0027] Referring to FIGS. 1 and 2, front and cross-sectional views
of an example embodiment of a trimmable surround 100 are shown. The
trimmable surround 100 may be comprised of any material that
provides a surface 102 that insulates a user of a fireplace from at
least one exposed surface of the fireplace. The trimmable surround
100 includes a molded portion 104 that includes a top portion 106,
and two side portions 108, 110.
[0028] Molded portion 104 can be formed from, for example,
inorganic ceramic fibers and a binder. Molded portion 104 can be
formed by any known molding technique, such as, for example,
compression molding, vacuum forming, or casting techniques.
Exemplary molding compositions and forming techniques are described
in pending United States Publication No. US-2003-0049575-A1, 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
patents are incorporated herein by reference in their entirety.
[0029] The top portion 106 and two side portions 108, 110 can
define an opening 111 that typically corresponds to the dimensions
of a glass panel that allows viewing into the fireplace. For
example, opening 111 is approximately 34 inches wide along
dimension W and 26 inches high along dimension X. These dimensions
can correspond to the opening of a number of gas fireplace inserts.
For example, the dimensions of opening 111 can be used with a
Hearth & Home Technologies (Lakeville, Minn.) fireplace insert
sold under the names of FB-GRAND. The side portions 108, 110 of
trimmable surround 100 can have a width Y of about, for example,
3-10 inches and preferably has a width of about 7 inches. The top
portion 106 can have a dimension Z of about, for example, 3-10
inches and preferably has a width Z of about 6 inches. Trimmable
surround 100 can be formed in any other desired size, shape and
configuration to the configuration shown in the Figures. For
example, trimmable surround can be formed and sized to cover
exposed surfaces of wood stoves or other combustion devices.
[0030] Surround 100 can be attached to a combustion device using,
for example, screws, bolts, or high temperature adhesives, and may
further require placing the surround in front of the combustion
device, sizing the surround to press fit into an opening, or
utilizing other attachment devices, such as the apparatus disclosed
in FIGS. 3-5.
[0031] Referring to FIGS. 3-5, another embodiment of a trimmable
surround 200 is shown. The trimmable surround 200 includes a molded
portion 204 having a top portion 206, and two side portions 208,
210. The top portion 206 and two side portions 208, 210 can define
an opening 211 having dimensions A, B (see FIG. 4), which
dimensions may be similar to dimensions Y, Z for surround 100.
[0032] Trimmable surround 200 also includes an attachment portion
212. The attachment portion 212 includes a right bracket 214, left
bracket 216, and a top bracket 218. Optionally included is a bottom
bracket 217. Although shown a multiple parts, alternatively,
attachment portion can be constructed as a single unit. Flanges
220, 221 extend from a bottom portion 222 of each of the right and
left brackets 214, 216.
[0033] Top bracket 218 includes air holes 224, 225, 226, 227 that
allow for the circulation of heated room air. Air holes 224, 225,
226, 227 are only one example of a construction that will allow for
the return of air into the room in which a fireplace is located.
Alternatively, a single air hole can be used, or if no circulation
of room air is desired, the air holes can be eliminated.
[0034] As shown in FIG. 4, the attachment portion 212 can be
screwed into a back surface 228 of the molded portion 204.
Alternatively, attachment portion 212 can be coupled to the molded
portion through other means, such as, for example, bolting,
adhering, or forming the attachment portion into the molded portion
during the molding process. The attachment portion 212 allows an
installer to couple the molded portion 204 to a combustion
device.
[0035] Trimmable surrounds 100, 200 can be manipulated in any
number of ways. In one method, a standard size surround is used and
can be trimmed by the consumer as desired. The consumer purchases
the trimmable surround, such as surrounds 100, 200, with the
intention of trimming the surround to a size that fits a particular
fireplace opening or exposed surface that is to be at least
partially covered with a finished surround.
[0036] A consumer can trim a surround to a desired size according
to the following example steps. After purchasing a trimmable
surround (such as 100, 200) of a desired size, shape, or dimension,
the consumer can utilize a template, which is either supplied by
the manufacturer or created by the consumer, to trace a combustion
device opening in which a combustion device is disposed. After
tracing the combustion device opening, the consumer cuts the
template and verifies that the finished template fits within the
combustion device opening. In some embodiments, the template may be
cut to a size larger or smaller than the combustion device opening
so that the trimmed surround properly overlaps or resides adjacent
to the combustion device opening as desired.
[0037] Once a final template is created, the inside opening of the
template is aligned with an opening (111, 211) of the trimmable
surround (100, 200) on a front surface of the trimmable surround
(100, 200). The consumer then traces around the template to mark
off the size of the combustion device opening. The consumer next
cuts or removes the excess portions of the trimmable surround (100,
200) off using a jig saw, skill saw, hand saw or other cutting
device. Cutting may be done along, for example, inner edges 203,
205 of the side portions 208, 210, or cutting may define the edges
203, 205. The consumer can leave the template in place on the front
surface (103, 203) of the trimmable surround (100, 200) during the
cutting process. Alternatively, the template can be removed prior
to cutting the trimmable surround (100, 200). In further
embodiments, the surround may be constructed so that the size
modifications to the surround can be made by breaking, bending, or
otherwise removing predetermined sections, strips, or other pieces
from the surround.
[0038] After cutting the trimmable surround (100, 200), the
consumer can paint or stain the outer surface facing (e.g., surface
102) of the surround to match the surrounding decor of the room or
fireplace structure. Staining a compression molded fiber material
may provide a marbleized or other specific look to the trimmable
surround depending on the fiber material and method of molding.
After preparing the finish on the trimmable surround (100, 200),
the surround can be installed onto the fireplace, insert, stove, or
other heat generating device.
[0039] Trimmable surround can also be manipulated in other ways.
For example, patterns, designs, initials, or other decorative
modifications can be made to the trimmable surround (100, 200)
prior to or after installation in the fireplace opening. Functional
modifications can also be made. For example, holes or openings can
be created in the trimmable surround (100, 200) to allow for air
passage around the fireplace. These types of modifications can be
made to the surround before or after the surround is installed
depending of the type of modification being made.
[0040] Referring to FIGS. 6-9, trimmable surround 200 is shown
coupled to a combustion device 250 (heat generating device), such
as a fireplace insert. Combustion device 250 is illustrated
including an outer enclosure 252 having a front panel 254, top
panel 256, back panel 258, and two side panels 260, 262.
[0041] Coupling of the trimmable surround 200 to front panel 254
can cover gaps, such as gap R shown in FIG. 10, between an existing
structure 264, such as a wall or masonry, and the combustion device
250 being covered. As shown in FIG. 10, the trimmable surround 200
can been sized to fit within an opening 279 in a wall 265 of the
existing structure 264. For example, if a height of the trimmable
surround 200 is too tall to fit within the opening of the wall 265,
an upper portion 281 of the surround 200 can be trimmed to lower
the surround and allow the surround to fit within the opening 279
in the wall 265. Likewise, side portions 208, 210 can be trimmed on
outer side edges 207, 209 (see FIG. 9) as necessary to conform to
the opening in a wall 265, or can be trimmed on inner edges 203,
205 (see FIG. 5) to properly cover the exposed surface 251 of the
combustion device 250. Similar modifications can be made to the top
portion 106 and side portions 108, 110 of trimmable surround
100.
[0042] The combustion device 250 may generally function to ignite
combustible gas provided from a combustible gas source to create a
gas flame. For example, a burner (not shown) can be positioned
within the combustion device 250, which generates heat that
increases the temperature of an exposed surface and the outer
enclosure 252. Often, when a surround is formed of a metal
material, the exposed surface is heated to a temperature that can
cause injury to an individual who touches the surface unless all or
a portion of the exposed surface is isolated from the heat to lower
the temperature of the exposed surface.
[0043] As shown in FIGS. 6-10, utilization of trimmable surround
200 provides a barrier between the user of the combustion device
250 and the exposed surface 251 (see FIG. 9), and minimizes the
amount of the exposed surface 251. This type of barrier may be
particularly relevant when surface 251 includes a metal or other
high heat conductive material. Trimmable surround 200 may be
composed of a ceramic fiber and a binder, which is a non-metallic
material. Another exemplary non-metallic material for surround 200
is fiberglass. In prior surround systems, metal is primarily used
as the material for covering gaps between the combustion device 250
and the existing wall or masonry of a structure.
[0044] Room air may be heated as it travels around the outer
enclosure 252. Optionally, a blower (not shown) can be used for
moving room air into and out of an area surrounding the combustion
device 250. An exhaust 266 exhausts combusted air from the
combustion device 250. The combustion device 250 may also include
an air intake 268 that facilitates bringing fresh combustion air
into the combustion device 250 for combustion.
[0045] Screws, bolts, high temperature adhesives, or other
attachment devices can be utilized to attach the trimmable surround
200 to the combustion device 250. For example, the trimmable
surround 200 may be coupled to device 250 with mounting screws that
pass through flanges 220, 221 and into lower portions 269, 270 of
the combustion device 250. As shown best in FIGS. 8A and 10A, the
top bracket 218 can include slots 271 that receive mounting tabs
273 of the combustion device 250.
[0046] FIGS. 6-10 show a combustion device in one configuration.
Other configurations are also possible. For example, the present
invention may be applicable to any prefabricated gas fireplace such
as a direct vent, a universal vent, a B-vent, a
horizontal/vertical-vent, a dual direct vent, or a multisided unit.
For a multi-sided fireplace such as the one disclosed in U.S. Pat.
No. 5,016,609, incorporated herein by reference in its entirety, a
single surround formed from a single molded piece, can be placed
over the multiple exposed sides of the multi-sided unit.
Alternatively, a multiple number of panels can be placed over each
exposed side of the multi-sided fireplace unit. The present
invention may also be applicable to free standing wood stoves and
wood inserts.
[0047] The present invention may also be applicable to other
combustible gas fireplace systems, as noted above, as well as any
other fireplace or device that generates heat such as a simulated
electric fireplace or solid fuel-burning fireplace. For example,
the simulated electric fireplace may be constructed within the
outer enclosure 252. The simulated electric fireplace can include
several electrical components such as a simulated ember bed,
lights, a heat source, and a blower.
[0048] As previously noted, the present invention is applicable for
use with fireplaces of varying sizes and shapes. The surround can
be trimmed and modified as needed to fit a given fireplace
configuration. For example, if a fireplace includes an arch-shaped
front panel, an upper portion of the opening of the surround can be
cut to conform to the arch-shaped front panel. If such a fireplace
is used, one or more pieces of the attachment portion, such as the
top bracket, can be removed if necessary and only the right and
left brackets used to couple the surround to the fireplace.
[0049] The example surrounds disclosed herein can be used to finish
a new fireplace installation or to refinish a fireplace that has
been previously installed. For example, existing fireplaces that
include metallic surrounds can be refinished using surrounds 100,
200 disclosed herein. If an existing metallic surround is to be
replaced, the metallic surrounds can be removed prior to
installation of the new surround, or the new surround can simply be
placed over the existing metallic surrounds.
[0050] 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.
* * * * *