U.S. patent application number 14/310030 was filed with the patent office on 2014-10-09 for method of manufacturing a refractory panel for a fireplace.
The applicant listed for this patent is Innovative Hearth Products LLC. Invention is credited to Joseph A. Benedetti.
Application Number | 20140298652 14/310030 |
Document ID | / |
Family ID | 46718146 |
Filed Date | 2014-10-09 |
United States Patent
Application |
20140298652 |
Kind Code |
A1 |
Benedetti; Joseph A. |
October 9, 2014 |
METHOD OF MANUFACTURING A REFRACTORY PANEL FOR A FIREPLACE
Abstract
A method of manufacturing a refractory panel. The method
comprises forming a textured surface of interconnected subpanels.
Adjacent ones of the sub-panels are partially separated from each
other by gaps located between edges of the adjacent subpanels.
Inventors: |
Benedetti; Joseph A.;
(Nashville, TN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Innovative Hearth Products LLC |
Nashville |
TN |
US |
|
|
Family ID: |
46718146 |
Appl. No.: |
14/310030 |
Filed: |
June 20, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13214412 |
Aug 22, 2011 |
8800547 |
|
|
14310030 |
|
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61446939 |
Feb 25, 2011 |
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Current U.S.
Class: |
29/890.03 |
Current CPC
Class: |
F23D 14/10 20130101;
F24C 3/006 20130101; Y10T 29/49 20150115; F24B 1/181 20130101; Y10T
29/49348 20150115; F24B 1/195 20130101; F24B 1/192 20130101; F24B
1/1957 20130101; Y10T 29/4935 20150115; F23D 14/46 20130101; F24B
1/198 20130101; F24B 1/18 20130101; F23D 14/70 20130101; F24B
1/1808 20130101; F24C 3/08 20130101; F23D 2213/00 20130101; Y10T
29/49826 20150115 |
Class at
Publication: |
29/890.03 |
International
Class: |
F24B 1/195 20060101
F24B001/195; F24B 1/181 20060101 F24B001/181 |
Claims
1. A method of manufacturing a refractory panel, comprising:
forming a textured surface of interconnected subpanels wherein
adjacent ones of the sub-panels are partially separated from each
other by gaps located between edges of the adjacent subpanels.
2. The method of claim 1, wherein forming the textured surface of
interconnected subpanels includes: forming hinges or welds between
some of the edges of the subpanels.
3. The method of claim 1, wherein forming the textured surface of
subpanels includes: providing a single sheet of refractory
material; and cutting through the single panel to form the
subpanels such that the subpanels remain connected to the single
sheet on at least one side.
4. The method of claim 1, further including bending the subpanels
such that portions of the subpanels are out of an average plane of
the refractory panel to thereby configure the textured surface as a
three-dimensional textured surface.
5. The method of claim 4, wherein the portions of the subpanels are
bowed out in a direction perpendicular to the average plane of the
refractory panel such that the bowed-out portions of adjacent ones
of the subpanels are bowed out in opposite directions.
6. The method of claim 5, wherein the bowed-out portions of
adjacent ones of the subpanels form alternating concave and convex
shaped surfaces with respect to a viewing location outside of the
fireplace.
7. The method of claim 1, wherein the average plane of the
refractory panel is arched with respect to a viewing location
outside of the fireplace.
8. The method of claim 1, wherein the average plane of the
refractory panel is planer with respect to a viewing location
outside of the fireplace.
9. The method of claim 1, wherein adjacent ones of each of the
sub-panels are partially separated from each other by the gaps
located between edges of each of the adjacent subpanels and the
sub-panels are located within an outer perimeter of the refractory
panel.
10. The method of claim 1, wherein the gaps allow the passage of
visible light through the planar or arched-shaped refractory
panel.
11. A method of manufacturing a refractory panel, comprising:
forming a textured surface of interconnected subpanels wherein
adjacent ones of each of the sub-panels are partially separated
from each other by gaps located between edges of each of the
adjacent subpanels and located within an outer perimeter of the
planar or arched-shaped refractory panel, wherein the gaps allow
the passage of visible light through the planar or arched-shaped
refractory panel.
12. A method of manufacturing a fireplace, comprising: forming
walls to define an enclosed space and at least one opening;
locating a refractory assembly inside of the enclosed space the
refractory assembly including a refractory panel, the refractory
panel positioned such that a textured surface of the refractory
panel can be viewed through the opening from outside of the
fireplace, the refractory panel including: interconnected
sub-panels forming the textured surface, wherein adjacent ones of
each of the sub-panels are partially separated from each other by
gaps located between edges of each of the adjacent subpanels and
located within an outer perimeter of the planar or arched-shaped
refractory panel, wherein the gaps allow the passage of visible
light through the planar or arched-shaped refractory panel.
13. The method of claim 12, wherein locating the refractory
assembly includes locating the refractory panel adjacent to one of
the walls that is a rear wall.
14. The method of claim 12, further including locating an
illumination source behind the refractory panel and adjacent to one
of the walls that is a rear wall.
15. The method of claim 14, wherein the illumination source
includes a low-BTU illumination burner.
16. The method of claim 12, further including positioning a light
reflecting panel behind the refractory panel and adjacent to one of
the walls that is a rear wall.
17. The method of claim 16, wherein a surface of the refractory
panel that opposes the light reflecting panel includes a diffuse
reflective finish or a translucent finish.
18. The method of claim 12, further including locating an
illumination source in front of the refractory panel.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Application Ser. No. 61/446,939, filed by Joseph A. Benedetti et
al. on Feb. 25, 2011, entitled "IMPROVED LINEAR FIREPLACE WITH
BURNER," and U.S. application Ser. No. 13/214,412, filed by Joseph
A. Benedetti et al. on Aug. 22, 2011, entitled "REFRACTORY PANEL
FOR A FIREPLACE," commonly assigned with this application and
incorporated herein by reference.
TECHNICAL FIELD
[0002] This application is directed, in general, to fireplaces and,
more specifically, to a refractory panel for a fireplace, and to a
method of manufacturing the refractory panel and fireplace
including the panel.
BACKGROUND
[0003] A trend in prefabricated fireplace design has been a
minimalist approach to the exterior of the fireplace, with a
minimum of exposed metal outside the interior viewing area.
Consequently, there is more emphasis on what is inside of the
fireplace to create visual interest. Thus, decorative interior
panels, interior lighting, loose media and logs have become more
significant design features. It is important, however, for such
features have a low production and operating costs, and have long
durability.
SUMMARY
[0004] One embodiment of the present disclosure is a method of
manufacturing a refractory panel. The method comprises forming a
textured surface of interconnected subpanels. Adjacent ones of the
sub-panels are partially separated from each other by gaps located
between edges of the adjacent subpanels.
[0005] Another embodiment is another method of manufacturing a
refractory panel. The method comprises forming a textured surface
of interconnected subpanels. Adjacent ones of each of the
sub-panels are partially separated from each other by gaps located
between edges of each of the adjacent subpanels and located within
an outer perimeter of the planar or arched-shaped refractory panel.
The gaps allow the passage of visible light through the planar or
arched-shaped refractory panel.
[0006] Another embodiment is a method of manufacturing a fireplace.
The method comprises forming walls to define an enclosed space and
at least one opening. The method comprises locating a refractory
assembly inside of the enclosed space the refractory assembly
including a refractory panel. The refractory panel is positioned
such that a textured surface of the refractory panel can be viewed
through the opening from outside of the fireplace. The refractory
panel includes interconnected sub-panels forming the textured
surface. Adjacent ones of each of the sub-panels are partially
separated from each other by gaps located between edges of each of
the adjacent subpanels and located within an outer perimeter of the
planar or arched-shaped refractory panel. The gaps allow the
passage of visible light through the planar or arched-shaped
refractory panel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Reference is now made to the following descriptions taken in
conjunction with the accompanying drawings, in which:
[0008] FIG. 1 presents a schematic front view of an example
embodiment of a refractory panel of the disclosure;
[0009] FIG. 2 presents a side view of the refractory panel of the
disclosure, similar to that depicted in FIG. 1, along view line 2
in FIG. 1;
[0010] FIG. 3 presents a schematic front view of an alternative
example embodiment of a refractory panel of the disclosure;
[0011] FIG. 4 presents a side view of the refractory panel of the
disclosure, similar to that depicted in FIG. 3, along view line 4
in FIG. 3;
[0012] FIG. 5 presents a cut-away perspective view of an example
embodiment of selected portions of a fireplace of the disclosure,
the fireplace including the disclosed refractory panel, including
any of the embodiments discussed in the context of FIG. 1-4;
and
[0013] FIG. 6 presents a flow diagram of an example method of
manufacture which includes fabricating a refractory panel,
including any of the example embodiments discussed in the context
of FIGS. 1-5.
DETAILED DESCRIPTION
[0014] The term, "or," as used herein, refers to a non-exclusive
or, unless otherwise indicated. Also, the various embodiments
described herein are not necessarily mutually exclusive, as some
embodiments can be combined with one or more other embodiments to
form new embodiments.
[0015] Embodiments of the present disclosure provide a refractory
panel for fireplaces which integrate decorative features and
utility features. By integrating decorative features into the
refractory panel, costs are eliminated or minimized compared to the
separate fabrication and installation of decorative structures in
the fireplace.
[0016] One embodiment of the present disclosure is a refractory
panel for a fireplace. FIG. 1 presents a schematic front view of an
example embodiment of a refractory panel 100 of the disclosure and
FIG. 2 presents a side view of an example refractory panel 100 of
the disclosure, similar to the panel 100 depicted in FIG. 1, along
view line 2 in FIG. 1.
[0017] The panel 100 comprises interconnected sub-panels 110
forming a textured surface 115, wherein adjacent ones of the
sub-panels 110 (e.g., sub-panels 112, 114) are partially separated
from each other by gaps 120 located between edges 125, 127 of the
adjacent subpanels 112, 114. In some cases adjacent subpanels 112,
114 are side-by-side. In other cases, (e.g., sometimes when the
textured surface 115 form a three-dimensional surface) portions of
the adjacent subpanels 112, 114 can overlap and can be separated by
a gap 120 in the dimension that is perpendicular to the average
plane 210.
[0018] The refractory panel 100, when installed in a fireplace 130,
can facilitate the distribution and adjustment of visible light
passing through the panel 100, and/or heat reflected off the panel
and subsequently sensed by individuals in the vicinity outside of
the fireplace 130. For instance, by increasing or decreasing the
size of the gaps 120 more or less light or heat can be directed out
of fireplace 130 opening 132. Similarly, adjusting the curvature of
the sub-panels 110 or the curvature of the panel 100, can adjust
the distribution and adjustment of visible light viewable, and/or
heat from the fireplace 130.
[0019] The textured surface 115 is visible from outside of the
fireplace 130 when the refractory panel 100 is installed in the
fireplace 130. For instance, a viewing location 202 (FIG. 2) from
which the textured surface 115 can be seen can be facing the
opening 132 in a fireplace box 130. In some cases, the refractory
panel 100 can be installed in a fireplace pit, or other fireplace
structure, such that the textured surface 115 is visible from an
opening in the fireplace.
[0020] In some embodiments the textured surface 115 is a two
dimensional surface with the subpanels 110 and gaps 120 being
entirely in a two-dimensional plane. In other embodiments, the
textured surface 115 is a three-dimensional textured surface. For
instance, portion of the subpanels 110 can protrude out from a
plane or average plane of the panel 110 to provide the
three-dimensional textured surface. For instance, as illustrated in
FIG. 2, in some embodiments, portions of at least some of the
subpanels 110 are bowed out in a direction 205, 207 that is
substantially perpendicular to an average plane 210 of the
refractory panel 100. In some cases, the bowed-out portions 215 of
adjacent ones of the subpanels 112, 114 are bowed out in opposite
directions 205, 207. For instance, in some cases the bowed-out
portions 215 of the adjacent ones of the subpanels 112, 114 can
form alternating concave and convex-shaped surfaces 220, 225 with
respect to the viewing location 202 outside of the fireplace 130.
In other cases, there can be more concave-shaped surfaces 220
facing the fireplace opening 132 than convex-shaped surfaces 225
facing the fireplace opening 132, e.g., to help direct more heat
out of the opening 132. In still other cases, there can be more
convex-shaped surfaces 225 than concave-shaped surfaces 220 facing
the opening 132. Based on the present disclosure, one skilled in
the art was appreciating that the surfaces 220 could have shapes
other than concave or convex, and that the subpanels 112, 114 can
have all the same size or different sizes. In some cases, for
instance, subpanels 112, with convex-shaped surfaces 225 can be
larger that subpanels 114 with concave-shaped surfaces 220, or,
vice-versa in other cases.
[0021] In some cases, the textured surface 115 of the whole panel
100 has an arched shape. For instance, as shown in FIG. 2 the
textured surface 115 can form a concaved-shaped arch (e.g., as
defined by an arching average plane 210) with respect to a viewing
location 132 outside of the fireplace 130. Such a configured can
facilitate the projection of more heat out of the opening 132 of
the fireplace. However, in other embodiments the textured surface
can form a convex-shaped arch with respect to a viewing location,
e.g., to facilitate the projection of less of heat out of the
fireplace opening. Based on the present disclosure one of ordinary
skill in the art would understand that the textured surface 115
could be configured to include other smooth or sharply angled
curvatures.
[0022] As illustrated in FIG. 1 in some cases, to present a uniform
visual appears, and in some cases, a uniform reflection of heat out
of the opening, all of the subpanels 110 can have substantially the
same area surface area (e.g., the areas of the subpanels forming
the textured surface are all the same within 10 percent). However,
in other cases, not all of the subpanels 110 have the same surface
area.
[0023] FIG. 3 presents a schematic front view of another an example
embodiment of the refractory panel 100 of the disclosure and FIG. 4
presents a side view of the refractory panel of the disclosure,
similar to the panel 100 depicted in FIG. 3, along view line 3.
[0024] For the embodiment shown in FIG. 3, the subpanels 110 are
interconnected through a base structure 310 of the refractory panel
100. In some cases, the base structure 310 can be a planar base
structure, while in other cases, the base structure 310 can have an
arched shape (e.g., as defined by the average plane 210 shown in
FIG. 4). As further illustrated in FIG. 3, three sides 320, 322,
324 of the subpanels 110 are separated from the planar base
structure 310 by gaps 120 (FIG. 4). However, in other cases, there
are only two sides (e.g., opposing sides 322 and 324) separated
from the planar base structure 310 by gaps 120. In still other
cases, a plurality of sides of multi-sided subpanels could be
separated from the planar base structure by gaps. In some cases, as
shown in FIG. 3, the same sides (e.g., bottom 320 and lateral sides
322, 324) of each of the subpanels 110 could be separated from the
planar base structure 310 by gaps 120. However, in other cases, the
different sides of different subpanels could be separated from the
planar base structure.
[0025] As further illustrated in FIG. 4, in some embodiments, all
of the subpanels 110 protrude in a same direction 410 that is
substantially perpendicular with respect to the base structure 310.
In other cases, however, some subpanels 110 protrude in one
perpendicular direction 205 and other subpanels 110 protrude in an
opposite perpendicular direction 207 with respect to the base
structure 310.
[0026] In some embodiments of the panel 100, such as shown in FIGS.
1-4, the subpanels 110 are part of a single continuous sheet of
refractory material, e.g., a continuous single sheet of steel or
other refractory material form well known to those skilled in the
art. In other cases however, the subpanels 110 can be separately
formed pieces that are coupled together to form the panel 100. For
instance, in some cases adjacent subpanels can be welded together
at their opposing edges or to a common base structure. For
instance, in some cases opposing edges of adjacent ones of the
subpanels are hinged together. E.g., edges of the subpanels can be
interlocked with a pin or interlaced without a pin, so that the
subpanels can are movable with respect to each other. Having
subpanels 110 that are hinged together can be independently moved
and angled with respect to each can facilitate the installation of
the refractory panel 100 in an existing fireplace 130. Having
hinged subpanels 110 can also facilitate forming different types of
curvature in the textured surface 115, e.g., to adjust the
distribution of heat and light reflection off of the textured
surface 115 as well as the amounts of light and heat passing
through the gaps between subpanels 110.
[0027] As further illustrated in FIG. 2, in some embodiments, the
refractory panel 100 is part of a refractory assembly 200 that can
further include one or both of a light reflecting panel 235 located
behind (relative to the viewing location 132 of the fireplace 130)
the refractory panel 100 and an illumination source 240 located
behind the refractory panel 100, and in some cases, between the
refractory panel 100 and light reflecting panel 235. In some cases,
the assembly 200 can include a housing 245 that holds the
refractory panel 100, light reflecting panel 235, and illumination
source 240 at fixed positions relative to each other.
[0028] Another embodiment of the disclosure is a fireplace that
includes the refractory panel of the disclosure. FIG. 5 presents a
cut-away perspective view of an example embodiment of selected
portions of a fireplace 130 of the disclosure.
[0029] The fireplace 130 comprises walls (e.g., side walls 510,
rear wall 514) defining an enclosed space 520 and at least one
opening 132. The fireplace 130 also comprises a refractory assembly
200 located inside of the enclosed space 520, and, positioned such
that a textured surface 115 of the refractory panel 100 of the
assembly 200 can be viewed through the opening 132 from outside of
the fireplace 130. The refractory panel 100 can include any of the
embodiments discussed in the context of FIG. 1-4. For instance, the
panel 100 includes interconnected sub-panels 110 forming the
textured surface 115 and adjacent ones of the sub-panels 112, 114
are partially separated from each other by gaps 120 located between
edges 125, 127 of the adjacent subpanels 112, 114 (FIG. 1).
[0030] As illustrated in FIG. 5, in some embodiments, the
refractory panel 100 (and assembly 200) is adjacent to a rear wall
514 of the fireplace 130. However in other embodiments, the
refractory panel 100 or, in some cases, multiple refractory panels
100, could be each adjacent to the side walls 510.
[0031] As illustrated in FIG. 5, in some embodiments, the
refractory assembly 200 further includes an illumination source 240
located behind (relative to the opening 132 and viewing location
202, FIG. 2) the refractory panel 100. The illumination source 240
can facilitate visual highlighting of the textured surface 115,
e.g., by providing back illumination respect to the viewing
location 202 (FIG. 2). In some cases, the illumination source 240
can be a low-BTU illumination burner (e.g., the burner capable of
maximally giving off 7000 BTUs or less of heat, and in some cases,
less than 5000 BTUs, and still other cases, heat in a range from
5000 to 7000 BTU). In other cases, the illumination source 240 can
be an incandescent light source (filament-type bulbs or neon light)
or a light emitting diode. In still other cases, illumination
source 240 can include a combination of one or more of a low-BTU
illumination burner, incandescent light source or light emitting
diode.
[0032] As illustrated in FIG. 5, in some embodiments, the
refractory assembly 200 includes a light reflecting panel 235
positioned behind (relative to the opening 132 and viewing location
202, FIG. 2) the refractory panel 100. The light reflecting panel
235 can facilitate the highlighting of the textured surface 115,
e.g., by reflecting the back-illumination from the illumination
source 240 and/or reflecting light coming from in front of the
textured surface 115 and passing through the gaps 120 in the
textured surface 115. In some cases, it is preferable for a surface
530 of the refractory panel 100 that opposes a rear surface 535 of
the refractory panel 100 to have a translucent finish (e.g., a
coating of white enamel porcelain paint) or a diffuse reflective
finish (e.g., brushed stainless steel finish). Having a translucent
finish or diffuse reflective surface can facilitate the uniform
distribution of the light being reflected off of the light
reflecting panel 235 and through the gaps 120 in the textured
surface 115.
[0033] In some cases, the surface 535 of the refractory panel 100
that opposes the light reflecting panel 235 includes a diffuse
reflective finish or a translucent finish, to facilitate reflecting
light not passing through the gaps 120 (FIGS. 1-3) to reflect back
off of the light reflecting panel 235 and out through the gaps 120
towards the viewing location 202.
[0034] As also illustrated in FIG. 5, some embodiments of the
fireplace 130 can further include an illumination source 540
located in front of (relative to the opening 132 and viewing
location 202) the refractory panel 100. In some cases, the front
illumination source 530 can be the primary heat source of the
fireplace 130, such as provided by a high BTU burner assembly 535
(e.g., a burner capable of putting 7000 BTUs or higher, e.g.,
30,000 or 60,000 BTUs), while in other cases, the illumination
source 540 can be or further include an incandescent light source
and/or LED sources.
[0035] Another embodiment of the present disclosure is a method of
manufacturing a refractory panel, such as any of the refractory
panels 100 discussed in the context of FIGS. 1-5. FIG. 6 presents a
flow diagram of an example method 600 of manufacture.
[0036] With continuing reference to FIGS. 1-5 throughout, the
example method 600 comprises a step 610 of forming a textured
surface 115 of interconnected subpanels 110 wherein adjacent ones
of the sub-panels (e.g., panels 112, 114) are partially separated
from each other by the gaps located between edges (e.g., edges 125,
127) of the adjacent subpanels 112, 114.
[0037] In some embodiments, forming the textured surface 115 of
interconnected subpanels 110 (step 610) can include a step 620 of
forming hinges or welds between some of the edges of the
subpanels.
[0038] In other embodiments, forming the textured surface 115 of
interconnected subpanels 110 (step 610) can include a step 630 of
providing a single sheet of refractory material (e.g., a steel
sheet) and a step 635 of cutting through the single sheet to form
the subpanels 110 such that the subpanels remain connected to the
single sheet on at least one side. In some embodiments, for
example, the single sheet is cut, as part of step 635, using a
laser or other metal cutting tool. One of ordinary skill would
understand that the sub-panels 112, 114 after step 635 remain
interconnected to each other either directly or through a base
structure 310 such as depicted in FIG. 3. For example, in some
cases such as shown in FIG. 1, one or more corner portions 140 of
the subpanels 112 can remain connected to adjacent subpanels 114,
e.g., by not cutting the single sheet corresponding to the corner
portion 140.
[0039] Certain embodiments of the method 600 can further include a
step 640 of bending the subpanels 110 such that portions 215 of the
subpanels 110 are outside of an average plane 210 of the refractory
panel 200 to thereby configure the textured surface 115 as a
three-dimensional textured surface.
[0040] In some cases the subpanels 110 can be individually bent in
step 640 prior to coupling the subpanels 110 together in step 620.
In other cases bending the subpanels 110 in step 640 further
includes placing the cut single sheet (e.g., the single sheet after
step 635) into a floating die and selectively bending portions of
the sheet such that the portions 215 of the subpanels 110 are
outside of an average plane 210.
[0041] Those skilled in the art to which this application relates
will appreciate that other and further additions, deletions,
substitutions and modifications may be made to the described
embodiments.
* * * * *