U.S. patent application number 12/032808 was filed with the patent office on 2009-08-20 for fireplace surround system and method of making same.
Invention is credited to Donald W. Ferguson, Robert W. Heath.
Application Number | 20090205263 12/032808 |
Document ID | / |
Family ID | 40953801 |
Filed Date | 2009-08-20 |
United States Patent
Application |
20090205263 |
Kind Code |
A1 |
Heath; Robert W. ; et
al. |
August 20, 2009 |
FIREPLACE SURROUND SYSTEM AND METHOD OF MAKING SAME
Abstract
A modular fireplace surround assembly for a fireplace opening is
formed from a plurality of surround components comprising a first
set of components, having a foam core and a manufactured stone
veneer shell, located at least 8 inches from the fireplace opening,
and a second set of components formed of entirely noncombustible
materials including manufactured stone veneer. The first set of
components are adapted to receive fasteners that pass through the
back member for either direct or indirect mounting to the wall. In
one embodiment, the first set of components includes a mantel shelf
formed of interconnected, main and top components. The second set
of components also establishes a front facing formed of a plurality
of modular, interchangeable blocks arranged about the top and sides
of the fireplace opening.
Inventors: |
Heath; Robert W.; (Napa,
CA) ; Ferguson; Donald W.; (Napa, CA) |
Correspondence
Address: |
OWENS CORNING
2790 COLUMBUS ROAD
GRANVILLE
OH
43023
US
|
Family ID: |
40953801 |
Appl. No.: |
12/032808 |
Filed: |
February 18, 2008 |
Current U.S.
Class: |
52/36.3 ;
126/500 |
Current CPC
Class: |
F24B 1/198 20130101;
E04F 19/005 20130101 |
Class at
Publication: |
52/36.3 ;
126/500 |
International
Class: |
F24B 1/198 20060101
F24B001/198 |
Claims
1. A modular fireplace surround assembly mounted around a fireplace
opening defined by top and side portions and being located in a
wall above a floor, said modular assembly comprising: a plurality
of surround components including a first set of components having a
foam core and a manufactured stone veneer shell and being located
at least 8 inches from the fireplace opening and a second set of
components formed of entirely noncombustible materials including
manufactured stone veneer and being mounted around the fireplace
opening above the floor and including a front facing having a
plurality of modular, interchangeable components arranged about the
top and side portions of the fireplace opening, a first component
of said second set of components having a lower end, an upper end,
and a first groove located in the upper end receiving fasteners
that pass through the first component into the wall and adapted to
be covered by a second component of said plurality of surround
components; and a mantel shelf having a lower main body and an
outer skin formed of a manufactured stone veneer, a reinforced back
member receiving fasteners that pass through the reinforced back
member into the wall, and a top component fitted onto the lower
main body whereby, when the top component is installed, the top
component creates a finished surface that conceals the
fasteners.
2. A fireplace surround assembly comprising: a plurality of
surround components adapted to be mounted around a fireplace
opening in a wall above a floor; and a mantel shelf including: a
lower main body; a back member adapted to receive fasteners that
pass through the back member into the wall; and a top component
adapted to fit onto the lower main body whereby, when the top
component is installed, the top component creates a finished
surface that conceals the fasteners.
3. The fireplace assembly of claim 2, further comprising: a
reinforcing member positioned against the back member within the
lower main body.
4. A fireplace surround assembly comprising: a plurality of
surround components adapted to be mounted around a fireplace
opening in a wall above a floor, said plurality of surround
components including a first component and a second component,
wherein the first component of said plurality of surround
components having a lower end, an upper end and a first groove
located in the upper end adapted to receive fasteners that pass
through the first component for mounting the first component to the
wall, and wherein the first component is covered by the second
component of said plurality of surround components.
5. The fireplace assembly of claim 4, wherein said first component
is a leg member adapted to be mounted to extend vertically along
the wall on one side of the fireplace opening.
6. The fireplace assembly of claim 5, wherein the leg member has an
outer skin formed of a manufactured stone veneer.
7. The fireplace assembly of claim 4, wherein said first component
is a corbel and the second component is a mantel shelf.
8. The fireplace assembly of claim 7, wherein the corbel has an
inner core formed of foam and an outer skin formed of a
manufactured stone veneer.
9. The fireplace assembly of claim 4, wherein said first component
is a lintel and the second component is a mantel shelf.
10. The fireplace assembly of claim 9, wherein the lintel has an
inner core formed of foam and an outer skin formed of a
manufactured stone veneer.
11. A modular fireplace surround assembly mounted around a
fireplace opening defined by top and side portions and being
located in a wall above a floor, said modular assembly comprising:
a plurality of components including first and second sets of
components, each of the first set of components having a foam core
and a manufactured stone veneer shell, with each of the first set
of components being located at least 8 inches from the fireplace
opening, each of the second set of components being formed of
entirely noncombustible materials including manufactured stone
veneer, with each of the second set of components being mounted
around the fireplace opening.
12. The modular fireplace surround of claim 11, wherein the first
set of components includes a mantel shelf.
13. The modular fireplace surround of claim 12, wherein the second
set of components includes a front facing constituted by a
plurality of modular, interchangeable components arranged about the
top and side portions of the fireplace opening.
14. The modular fireplace surround of claim 13, further comprising:
a hearth member mounted on the floor below the fireplace opening,
wherein the second set of components includes a pair of adjustable
plinth stones mounted on the hearth member.
15. The modular fireplace surround of claim 13, wherein the first
set of components includes a pair of leg members extending
vertically along the wall on opposite sides of the fireplace
opening.
16. The modular fireplace surround of claim 13, wherein the first
set of components includes a pair of corbels adapted to be mounted
below the mantel shelf.
17. The modular fireplace surround of claim 13, wherein the first
set of components includes a lintel member adapted to be mounted
below the mantel shelf and across the fireplace opening.
18. A method of forming a modular fireplace surround assembly
around fireplace opening having top and side portions and being
located in a wall above a floor comprising: selecting a first array
of desired fireplace surround components from a first set of
components having a manufactured stone veneer shell; selecting a
second array of desired fireplace surround components from a second
set of components formed of entirely noncombustible materials
including manufactured stone veneer; temporarily mounting the first
array of desired fireplace surround components around the fireplace
opening through the use of mechanical fasteners; permanently fixing
the first array of desired fireplace surround components around the
fireplace with an adhesive material; and mounting the second array
of desired fireplace surround components around the fireplace
opening and between at least some of the first array of desired
fireplace surround components.
19. The method of mounting of claim 18, wherein temporarily
mounting the first array of desired fireplace surround components
includes: mounting a pair of leg members on the wall by passing at
least one fastener into a groove in each leg member and into the
wall; mounting a lintel on the wall above the fireplace opening by
passing fasteners into a groove in the lintel and into the wall;
and covering the grooves and fasteners with at least one of said
first set of components.
20. The method of mounting of claim 18, wherein mounting the second
array of desired components comprises: mounting a hearth on the
floor below the fireplace opening; and installing a front facing,
including a plurality of modular, interchangeable components each
formed of an artificial stone veneer, by fixing the front facing in
a desired pattern between the hearth and the first array of desired
fireplace surround components.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention pertains to the art of fireplaces and,
more particularly, to manufactured stone veneer assemblies for
surrounding fireplace openings.
[0003] 2. Discussion of the Prior Art
[0004] Interior fireplaces are often located in houses or other
buildings such as hotels, restaurants, etc. to provide heat and
also to add to the aesthetic appeal. Usually the fireplace is
located in a wall of the house and has a fireplace opening so that
the occupants of the home may tend to a fire in the fireplace and
the fireplace can radiate heat into the house. The brick, stone,
other masonry or wood detail surrounding a fireplace opening is
known in the art as a decorative fireplace surround. Fireplace
surrounds are commonly used to enhance the look and feel of a
fireplace and also function to cover otherwise unsightly features
of the fireplace, such as fireplace vents or the unfinished
interface between the fireplace and the wall structure. Most
commonly, surrounds are masonry structures prepared brick-by-brick
or stone-by-stone by highly skilled and highly paid workers.
Traditional brick or stone surrounds, for example, are composed of
numerous individual bricks separated from each other by grout or
mortar recessed between the bricks. The bricks are of uniform
shape, but one row of bricks is offset from adjacent rows so that
the grouted vertical spaces between bricks do not line up from row
to row. While such a structure is quite durable, it is also quite
expensive to construct.
[0005] Such surrounds may also include a mantel shelf that extends
horizontally above the fireplace, and two legs that extend
vertically along opposing sides of the fireplace. The mantel shelf
and legs are often secured together as a single assembled piece
that is mounted to the wall structure surrounding the fireplace. In
other applications, the mantel shelf and leg members may be
individually mounted to the wall structure surrounding the
fireplace. It is sometimes also desirable to provide additional
shelving and/or bookcase structure around the fireplace opening for
supporting and displaying, for example, photographs, books and the
like.
[0006] There have been attempts to provide fireplace surround
assemblies that have the appearance of real brickwork but are made
from artificial materials. Generally, such artificial surround
assemblies have been molded from cement compounds that are formed
to simulate the texture of actual brick and then colored with dye
or paint to imitate the appearance of brick. For purposes of
installation, such molded surrounds are usually cast as two units,
i.e., a vertical legs and lintel unit and a horizontal hearth unit,
which are positioned around a fireplace opening.
[0007] Unfortunately, affixing mantel shelves, legs or other
surround components to the support wall can be difficult and time
consuming. One known method includes applying an adhesive between
the support wall and the surround component. A metal lath is placed
on the wall and secured, then an adhesive, such as Portland cement
(mortar), is spread on the lath and the fireplace surround
component. The surround component is then placed against the lath.
When the cement dries, the surround components are securely held in
place. However, using a metal lath requires cutting, is expensive
and sometimes difficult to install. Also, during construction of a
building, hammering and other activities regarding the construction
of a building may be taking place. Often the mantel shelf and legs
may be displaced by other construction activities before the
adhesive has dried. As a result, the mantel shelf, legs and other
components may be positioned at an odd angle when the adhesive
dries, giving an undesirable look and usually requiring an
expensive fix.
[0008] Another proposed solution includes attaching a number of
individual hooks to the support wall at the locations of wall
studs. The method also includes attaching a number of hooks on the
back of the mantel shelf or other surround components that engage
the hooks on the wall. Once each of the hooks is properly
positioned and affixed to the wall, the hooks on the mantel shelf
are aligned with the hooks on the wall and the mantel shelf is hung
on the wall. This method suffers in that it can be cumbersome and
time consuming to properly position the hooks on the wall and the
mantel shelf.
[0009] Based on the above there is a need in the art for a
fireplace surround that is formed of inexpensive yet aesthetically
appealing components that may be customized to different sized
fireplaces and is easily installed by unskilled workers in a work
environment subject to vibration caused by other construction
activities.
SUMMARY OF THE INVENTION
[0010] The present invention is directed to a modular fireplace
surround assembly adapted to be mounted to a support wall around a
fireplace. The modular fireplace surround is formed from a
plurality of surround components selected from first and second
sets of components. In the first set of components, each component
has a foam core and a manufactured stone veneer shell. These light
weight components include non-noncombustible materials and are
located at least eight (8) inches (at least approximately 20 cm)
from the fireplace opening. In the second set of components, each
component is formed of entirely noncombustible materials, and these
components are formed from a manufactured stone veneer, such as
lightweight concrete or glass reinforced concrete.
[0011] The fireplace surround is modular and, prior to
installation, is customized by a consumer who may pick and choose
components considered to be desirable by the consumer. Each of the
components may be mounted to the support wall in various layouts. A
fireplace surround according to a preferred embodiment of the
invention may have one or more of the several components discussed
below.
[0012] A mantel shelf is one of the more common surround
components. The mantel shelf may be mounted in two preferred ways.
In a first preferred embodiment, a metal track is mounted in the
wall above the fireplace opening and brackets are mounted to the
back of the mantel shelf. The mantel shelf is formed with a foam
core and an outer shell. The foam core makes the mantel shelf
relatively light and thus a workman can easily lift the mantel
shelf and engage the brackets on the mantel shelf with the track on
the wall. Additionally, the workman can put an adhesive, such as
Thinset mortar or latex adhesive, on the back of the mantel shelf
if a more secure connection is desired. The brackets will
permanently hold the mantel shelf in place until the adhesive sets.
In an alternative embodiment, the mantel shelf has a lower hollow
main body with a reinforced back member adapted to receive
fasteners that pass through the back member into the support wall.
Such a connection is sufficient to permanently hold the mantel
shelf in place, but adhesive may be used if desired. A top
component is installed over the open upper portion of the main body
and creates a finished surface that conceals the fasteners.
[0013] Some of the surround components are provided with a groove,
located in a top surface, adapted to receive fasteners that pass
through the component into the support wall and, when installed,
the grooves are covered by a second component. Corbels, lintels and
legs are examples of surround components that fall into this
category. As discussed, each of these components is formed with an
inner foam core and an outer shell formed of manufactured stone
veneer however, the shell may be hollow. Surround components
located near the fireplace opening are formed of solid manufactured
stone veneer, such as glass reinforced concrete. Hearthstones,
plinth stones, corbels, lintels and front facing blocks are
examples of components that fall into this category. Finally, a
front facing is constituted by a plurality of modular,
interchangeable stone components arranged about the top and sides
of the fireplace opening. These components may be placed anywhere
in the surround but are shown framed by a mantel shelf on top, legs
on the sides, and a hearth below. It should be understood that the
components could be brick, marble or granite tiles, slabs, or stone
pieces as well.
[0014] When a workman installs the fireplace surround, the
following method is typically used. A consumer selects a first
array of desired components from the first set of components each
having a foam core and a manufactured stone veneer shell designed
to be located at least eight (8) inches (20 cm) from the fireplace
opening. A consumer then selects a second array of desired
components from the second set of components formed of entirely
noncombustible materials including manufactured stone veneer or
other noncombustible facing materials such as natural stone, brick,
granite, or limestone tile etc. The first array of desired
components are temporarily mounted in the fireplace surround. For
example, a pair of leg members is mounted on the wall by passing
fasteners through a groove in each of the leg members and into the
wall. The grooves and fasteners are then covered with another of
the plurality of components, such as a pair of corbels or a mantel
shelf. Likewise, a pair of corbels is mounted on the wall by
passing fasteners through a groove in each of the corbels into the
wall, with the groove and fastener being covered by the mantel
shelf. A lintel is mounted on the wall above the opening by passing
fasteners through a groove in the lintel into the wall and covering
the groove and fastener with the mantel shelf. The mantel shelf is
generally the last of the components to install. A hearth is
mounted on the floor below the opening when the surround is placed
around a wood fireplace. A pair of adjustable plinth stones is
placed on the hearth. A front facing, including a plurality of
modular, interchangeable components each formed of an artificial
stone veneer, is placed between the mantel shelf and the hearth in
a desired pattern and fixed in place with an adhesive.
Additionally, selected components can be installed on the support
wall.
[0015] With this arrangement, a fireplace surround can be quickly
and inexpensively installed on site. Additional objects, features
and advantages of the present invention will become more readily
apparent from the following detailed description of preferred
embodiments when taken in conjunction with the drawings wherein
like reference numerals refer to corresponding parts in the several
views.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a perspective view of the front of a fireplace
surround according to a first preferred embodiment of the invention
showing an arrangement with a lintel and mantel shelf across the
top of the fireplace facing materials and legs outside a modular
facing;
[0017] FIG. 2 is a perspective view of the front of a fireplace
surround according to a second preferred embodiment of the
invention showing an arrangement with a mantel shelf, corbels and a
trim on the inside and outside of a modular facing;
[0018] FIG. 3 is a cut-away view of the surround of FIG. 2 showing
a connection between the mantel shelf and a wall;
[0019] FIG. 4 is a cross-sectional view of the mantel shelf of FIG.
3 showing mounting clips;
[0020] FIG. 5 is a cross-sectional view of the mantel shelf of FIG.
2 showing a two-piece arrangement;
[0021] FIG. 6 is a perspective view of one of the corbels of FIG.
2;
[0022] FIG. 7 is a cross-sectional view of the corbel of FIG. 6
taken along the line 7-7;
[0023] FIG. 8 is a perspective view of one of the legs of FIG.
1;
[0024] FIG. 9 is a cross-sectional view of the leg of FIG. 8 taken
along the line 9-9;
[0025] FIG. 10 is a perspective view of the lintel of FIG. 1;
and
[0026] FIG. 11 is a cross-sectional view of the lintel of FIG. 10
taken along the line 11-11.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] With initial reference to FIG. 1, there is shown an
exemplary fireplace 20, having an associated chimney 21, located in
a support wall 22 of a house or other building 23. As shown, the
fireplace 20 is a pre-manufactured fireplace having a front opening
24. Vents 26 may be provided above and below a firebox 28 to allow
air to circulate and provide better heating efficiency. A pair of
glass doors 30 is provided to allow people to tend to the fireplace
20. The doors 30 may be left closed or open as desired. When the
fireplace 20 is not is use, the doors 30 are typically left shut in
order to prevent air from escaping up the chimney 21. The fireplace
20 may be a conventional wood fireplace or may be fueled by natural
gas, propane or other sources.
[0028] A fireplace surround assembly 40 is adapted to be mounted on
a support floor 41 and to the support wall 22 around the fireplace
20. The surround assembly 40 is modular and formed from a plurality
of surround components 42. A consumer who may pick and choose
components that he considers desirable to customize the surround
assembly 40. Each of the components may be mounted to the support
wall 22 in various configurations. In accordance with a preferred
embodiment of the present invention, surround assembly 40 may have
one or more of the several components discussed below. The surround
assembly 40 shown in FIG. 1 is just an example of one possible
configuration. Another configuration will be discussed below in
reference to FIG. 2. However, it should be readily understood that
various configurations are possible.
[0029] With reference to FIG. 1, a hearth extension 44 is required
for wood burning fireplaces and is formed of several hearthstones
46. Even though the hearth extension 44 is not required for gas or
electric fireplace installation, hearthstones 46 are commonly used
for aesthetic appeal. When used with a wood fireplace, the
hearthstones 46 must be non-combustible and extend at least 16
inches (40 cm) from the firebox 28. If the front opening 24 is more
than 3 square feet, the hearth extension 44 should be at least 20
inches (40 cm). The hearth extension 44 must also meet any other
heat resistant requirements for the selected manufactured firebox
28. The hearthstones 46 are typically formed of concrete or glass
reinforced concrete and are 11/2 inches (approximately 4 cm) thick,
12 inches (30 cm) long and 20 inches (51 cm) wide and formed in
several different lengths. The hearthstones 46 are installed in a
conventional manner by attaching a metal lath 47 over a prepared
surface of the floor 41 with fasteners 48 that penetrate the floor
41 to a depth in the order of 5/8 of an inch. The hearthstones 46
are then set in a full setting bed of masonry or thin set mortar
49. Lath 47 is not required on noncombustible floors, such as those
made with concrete slabs. Optionally, there may be preformed
recessed cavities, such as 3/8''.times.3/8'' recesses (not shown),
on the hearth stones to accommodate grout joints.
[0030] Plinth stones 50 are used as a decorative trim component at
the base of the fireplace surround assembly 40. The plinth stones
50 are formed of solid manufactured stone veneer, such as glass
reinforced concrete. The plinth stones 50 are installed using lath
47 and masonry or thin set mortar 49. Also, latex construction
adhesives may be used in areas that do not have non-combustible or
heat requirements set by the fireplace manufacturer.
[0031] Around the top 52 and sides 53, 54 of the fireplace opening
24, a front facing 55 is formed of manufactured stone veneer and
may either be a preformed or precut panel 57 as shown in FIG. 1 or
may be a plurality of modular, interchangeable components pieces or
blocks 59 as shown in FIG. 2. When utilized, stone components,
pieces or blocks 59 are placed in the surround assembly 40. In
either case, the front facing 55 is installed on a metal lath
substrate 60 with masonry or installed with Thinset mortar 62 or,
if sufficiently far away from the firebox 28, it is typically
secured with latex construction adhesives.
[0032] In FIG. 1, the facing 55 is framed by a lintel 63 on top,
legs 64 on the sides, and plinth stones 50 below. A cove molding 66
is placed at the inner edges 67 of the manufacture stone veneer of
the front facing 55. The cove molding 66 is made of manufactured
stone veneer, which is typically made of glass reinforced concrete
and installed by adhering the cove molding 66 to an inner edge 67
of the abutting front facing 55 next to the firebox opening 24
using adhering materials that meet the non-combustible and heat
performance requirements for the associated firebox 28. A mantel
shelf 70 is located above the lintel 63.
[0033] In FIG. 2, the front facing 55 is framed by a mantel shelf
70 on top and hearth extension 44 below. A cove molding 66' is
placed at outer edges 77 of the manufacture stone veneer of the
front facing 55. The cove molding 66' is adhered to a sheathing
(not shown) of the support wall 22 away from the firebox 28 so that
adhesives, such as latex construction adhesive, may be used instead
of a lath and mortar. A preformed architectural trim 80 is placed
around the firebox 28 and is used at inner edges 81 of the front
facing 55. The preformed architectural trim 80 is made of
manufactured stone veneer, which is made of precast lightweight
concrete. The preformed architectural trim 80 is adhered to the
edges 81 of the front facing 55 and the substrate or metal lath 60
next to the opening 24 using adhering materials that meet the
non-combustible and heat performance requirements for the
associated firebox 28. If the preformed architectural trim 80 is
adhered to the sheathing of the support wall 22 away from the
firebox 28 other adhesives, such as latex construction adhesive may
be used.
[0034] Referring now to FIGS. 3 and 4, the mantel shelf 70 is
formed of a 5/16-inch shell 82 of manufactured stone veneer coated
onto five sides of an expanded polystyrene core 88. A reinforced
back side 90 of the polystyrene core 88 is finished with a polymer
cementitious skim coat over a fiberglass matt. The mantel shelf 70
may be mounted in various ways. In one embodiment as best seen in
FIGS. 3 and 4, a reinforcing back member in the form of a metal
track 100 is mounted in the wall 22 with fasteners 101 above the
fireplace opening 24 and brackets 110 are mounted to back 90 of the
mantel shelf 70. The foam core 88 makes the mantel shelf 70
relatively light and thus a workman can easily lift the mantel
shelf 70 and engage the brackets 110 on the mantel shelf 70 with
the track 100 on the wall 22 to form an overall mantel shelf
assembly. The workman will typically put an adhesive, such as
Thinset mortar or a latex adhesive Portland cement mortar, on the
back 90 of the mantel shelf 70 for a more secure permanent
connection, and the brackets 110 will hold the mantel shelf 70 in
place until the adhesive sets. For mantel shelf 70, brackets 110
are fastened into the wall studs and are a primary support, with
the adhesives being a secondary support. In an alternative
embodiment, a mantel shelf 70' shown in FIG. 5 is configured as a
two-piece arrangement and has a lower hollow main body 112 with an
integrated, internal reinforced back member 113 adapted to receive
fasteners 115 that pass through the back member 113 into the wall
22. Such a connection is sufficient to permanently hold the mantel
shelf 70' in place, but adhesive may also be used if desired. A top
component 116 is installed over the open upper portion of the main
body 112 and creates a finished surface that conceals the fasteners
115. In this embodiment, a metal lath does not need to be used.
[0035] Referring now to FIGS. 1-3 and 6-11, some components 120 of
the assembly 40, such as corbels 130, 131, are provided with a
groove 132 adapted to receive fasteners 133 that pass through the
component 120 and into the wall 22. Grooves 132 and fasteners 133
are then covered by a second component, such as the mantel shelf 70
when installed, such that the fasteners 133 are hidden from view.
Corbels 130 and 131, legs 64 and a lintel 63 are examples of
components 120 that fall into this category. Each of these
components 120, except the corbel 130 in FIG. 7, is formed with an
inner foam core 150, such as a polystyrene foam core, and an outer
shell 155 formed of GFRC (glass fiber reinforced concrete)
manufactured stone veneer. As best seen in FIGS. 2, 3, 6 and 7,
corbels 130, 131 are used as decorative trim and are also used as
additional support for the mantel shelf 70. A back side 160 of the
inner core 150 is finished with a polymer cementations skim coat
over a fiberglass matt.
[0036] Referring now to FIGS. 1, 8 and 9, legs 64 are used as
decorative trim and are also used as additional support for the
mantel shelf 70. The legs 64 are formed with a shell 175 of
manufactured GFRC stone veneer coated onto five sides of an
expanded, polystyrene core 176. A back side 180 of the core 176 is
finished with a polymer cementations skim coat over a fiberglass
matt. In the embodiments shown, each leg 64 is integrally formed
with a respective corbel 185 such that each leg 64 has a groove 181
in its top surface 183 adapted to receive fasteners 184 to be
covered by another component 42, such as mantel shelf 70 as shown
in FIG. 1.
[0037] Referring now to FIGS. 1, 10 and 11, the lintel 63 is used
as a decorative trim component under the mantel shelf 70 between
the fireplace surround legs 64. The lintel 63 is typically formed
of a 5/16 inch (0.8 cm) shell 186 of GFRC manufactured stone veneer
coated onto five sides of an expanded polystyrene core but may also
be made as a multi-piece unit, such as a three-piece unit. In
addition, the lintel 63 may be made without foam. A back side 190
of the core 187 is finished with a polymer cementations skim coat
over a fiberglass matt. If the lintel 63 has to be cut to a certain
length during installation, then the resulting exposed polystyrene
core 187 is concealed when installed against the manufactured stone
veneer of the side of the associated leg component 64. In
construction similar to the corbels, the lintel 63 has grooves 191
in its top surface 193 adapted to receive fasteners 194 and be
covered by another component 42, typically the mantel shelf 70.
[0038] As can be seen from the above discussion, the surround
assembly 40 can use two types of components 42. A first set of
components has a foam core and a GFRC manufactured stone veneer
shell. The foam core makes these components light, but since they
are not made entirely of noncombustible materials they are located
at least 8 inches (20 cm) from the fireplace opening. A second set
of components is formed of entirely noncombustible materials and
these components are formed from a manufactured stone veneer, such
as glass reinforced concrete or lightweight concrete. In one
embodiment, the method of establishing the surround assembly 40
includes having first array of desired components selected from a
first set of components having a foam core and a manufactured stone
veneer shell designed to be located at least 8 inches (20 cm) from
the fireplace opening. For example, legs and lintels and
mantel/shelves can be in the first array An array set of desired
components is also selected from a second set of components formed
of entirely noncombustible materials including manufactured stone
veneer. For example, hearthstone or plinth stones and cove moldings
can be in the second array.
[0039] The desired components from the first set of components are
temporarily mounted around the fireplace opening. For example, in
accordance with the embodiment of FIG. 1, hearth stones 46 are
initially installed first and then plinth stones 50 are mounted
thereon. The pair of leg members 64 are mounted on the wall 22
above plinth stones 50 by passing respective fasteners 184 into the
groove 181 in each of the leg members 64 into the wall 22. Next,
the second set of entirely fire resistant components defined by the
facing 55 is mounted. The lintel 63 can then be mounted on the wall
22 above the opening 24 and between the integral corbels 185 of leg
members 64 by passing the fasteners 194 through the grooves 191 in
the lintel 63 and into the wall 22. The mantel shelf 70 is mounted
over the leg members 64 and lintel 63 so as to cover the grooves
181, 191 and fasteners 184, 194. The mantel shelf 70 is mounted in
one of two ways. More specifically, the one-piece mantel shelf 70
is mounted by first mounting the track 100 over the fireplace
opening 24 with fasteners 101. The mantel shelf 70 is then lifted
in place so as to engage brackets 110 embedded in the mantel shelf
70 with the track 100. With the second embodiment of the mantel
shelf 70', fasteners 115 are placed through the reinforced back 113
of the hollow main body 112 and the top component 116 is then put
in place to hide the fasteners 115 and give a finished appearance.
To complete the assembly, cove molding 66 is provided. Assembly of
the fireplace surround assembly shown in FIG. 2 is carried out in a
similar manner as to that shown in FIG. 1. Therefore, when corbels
130, 131 are employed, corbels 130, 131 are mounted on the wall 22
by passing fasteners 133 into the grooves 132 in each of the
corbels 130, 131 and into the wall 22. Again, the grooves 132 and
the fasteners 133 would be covered with the mantel shelf 70. The
front facing 55, including the plurality of modular,
interchangeable components 59, each formed of an artificial stone
veneer, is placed between the mantel shelf 70 and the hearth
extension 44 in a desired pattern and fixed in place with an
adhesive. The components can also be installed in other sequences,
i.e., starting with components next to the firebox opening and
installing remaining components as work continues outward from the
firebox opening.
[0040] Although described with reference to preferred embodiment of
the invention, it should be readily understood that various changes
and/or modifications can be made to the invention without departing
from the spirit thereof. For instance, a fireplace surround
assembly may be made entirely with front facing of interchangeable
blocks and not include a mantel shelf or a hearth extension. In
fact, given that a consumer can readily pick and choose desired
components from the first and second arrays, a wide range of
readily producible fireplace surround assemblies can be
established. In addition, it should be realized that the order of
assembly of the components as set forth herein could readily be
altered without affecting the overall, final fireplace surround
system construction. Components described as having a foam core can
also be made with fire resistant hollow core GFRC. In general, the
invention is only intended to be limited by the scope of the
following claims.
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