U.S. patent application number 14/318728 was filed with the patent office on 2014-10-23 for method of manufacturing a fireplace screen.
The applicant listed for this patent is Innovative Hearth Products, LLC. Invention is credited to Paul Dusky, Brian Fowler.
Application Number | 20140310929 14/318728 |
Document ID | / |
Family ID | 46125804 |
Filed Date | 2014-10-23 |
United States Patent
Application |
20140310929 |
Kind Code |
A1 |
Fowler; Brian ; et
al. |
October 23, 2014 |
METHOD OF MANUFACTURING A FIREPLACE SCREEN
Abstract
A method of manufacturing a fireplace screen. The method
includes forming a mesh structure. The mesh structure is shaped to
cover a fireplace opening and holes in the mesh are configured to
promote the inflow of air external to a fireplace through the mesh
and a vertical circulation of the air across an interior planar
surface of the mesh located outside of the fireplace opening.
Inventors: |
Fowler; Brian; (Christiana,
TN) ; Dusky; Paul; (Greenbrier, TN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Innovative Hearth Products, LLC |
Nashville |
TN |
US |
|
|
Family ID: |
46125804 |
Appl. No.: |
14/318728 |
Filed: |
June 30, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12955006 |
Nov 29, 2010 |
8800546 |
|
|
14318728 |
|
|
|
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Current U.S.
Class: |
29/6.1 ; 29/428;
29/460; 29/896.6 |
Current CPC
Class: |
F24B 1/192 20130101;
Y10T 29/49888 20150115; Y10T 29/496 20150115; Y10T 29/18 20150115;
Y10T 29/49826 20150115 |
Class at
Publication: |
29/6.1 ;
29/896.6; 29/428; 29/460 |
International
Class: |
F24B 1/192 20060101
F24B001/192 |
Claims
1. A method of manufacturing a fireplace screen, comprising:
forming a mesh structure, wherein the mesh structure is shaped to
cover a fireplace opening and holes in the mesh are configured to
promote the inflow of air external to a fireplace through the mesh
and a vertical circulation of the air across an interior planar
surface of the mesh located outside of the fireplace opening.
2. The method of claim 1, wherein a total number of openings per
unit area of a central planar surface of the mesh structure is
different for different regions of the central planar surface.
3. The method of claim 1, wherein forming the mesh structure
includes bending one or more ends of the mesh structure to form a
beveled surface that has an incident angle relative to central
planar surface of the mesh structure.
4. The method of claim 1, wherein forming the mesh structure
includes: providing a sheet; forming openings in the sheet; and
expanding the sheet to increase a surface area of the sheet.
5. The method of claim 1, wherein forming the mesh structure
includes: forming lines in a sheet; and bending the sheet to form
corners along the formed lines with a central planar surface that
is offset from ends of the bent sheet.
6. The method of claim 1, wherein forming the mesh structure
includes: forming notches in a sheet; and bending ends of the sheet
along bend lines defined by the notches to form hooks configured to
fit over an edge of a transparent panel that is configured to cover
the fireplace opening.
7. The method of claim 1, wherein forming the mesh structure
includes: weaving two or more wires together so as to form a planar
lattice sheet with the holes therein; and cutting and bending the
planar lattice sheet to form the mesh structure.
8. The method of claim 7, wherein the wires are composed of a metal
material
9. The method of claim 7, wherein the wires are composed of a
ceramic material.
10. The method of claim 1, further including coating the mesh
structure with a thermally insulating material.
11. The method of claim 10, wherein the thermally insulating
material is a urethane-based thermally insulating material.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Non-Provisional
Application Ser. No. 12/955,006, filed by Brian Fowler, et al., on
Nov. 29, 2010, entitled "A FIREPLACE SCREEN," incorporated herein
by reference.
TECHNICAL FIELD
[0002] This application is directed, in general, to fireplace
screens, fireplaces, and methods of manufacturing thereof.
BACKGROUND
[0003] Fireplace screens have been used to prevent embers of
burning wood from being discharged from the fireplace into a room,
or, to reduce the risk of a person from directly touching the fire
or other hot objects. In some cases, a glass panel enclosure can be
installed to cover the fireplace opening.
SUMMARY
[0004] One embodiment of the present disclosure is a method of
manufacturing a fireplace screen. The method includes forming a
mesh structure. The mesh structure is shaped to cover a fireplace
opening and holes in the mesh are configured to promote the inflow
of air external to a fireplace through the mesh and a vertical
circulation of the air across an interior planar surface of the
mesh located outside of the fireplace opening.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Reference is now made to the following descriptions taken in
conjunction with the accompanying drawings, in which:
[0006] FIG. 1A presents an exploded schematic front view of an
example embodiment of a fireplace screen and fireplace of the
disclosure;
[0007] FIG. 1B presents a detail view of the mesh structure of an
example embodiment of a fireplace screen and fireplace of the
disclosure, such as the screen depicted in FIG. 1A;
[0008] FIG. 2 presents an exploded side view of the fireplace
screen and fireplace presented in FIG. 1A, along view line 2 as
depicted in FIG. 1;
[0009] FIG. 3 presents a flow diagram of an example method of
manufacturing a fireplace screen, such as any of the screens
depicted in FIGS. 1A-2; and
[0010] FIG. 4 presents a plan view of an example fireplace screen
at an intermediate stage of manufacture such as presented in the
example method depicted in FIG. 3.
DETAILED DESCRIPTION
[0011] Embodiments of the present disclosure mitigate the risk of
burn injury from the heating of fireplace screens or glass panel
enclosures covering a fireplace opening. The fireplace screen of
the present disclosure is designed so as to dissipate heat such
that the exterior surface of the screen remains within acceptable
thermal mass or heat transfer efficiency, when a fireplace to which
it is attached is generating heat. For instance, the acceptable
thermal mass or heat transfer efficiency would be low enough that
incidental transfer of heat energy to human skin contact remains
below an acceptable limit.
[0012] One embodiment of the present disclosure is a fireplace
screen. FIG. 1A presents an exploded schematic front view of an
example embodiment of a fireplace screen 100 and fireplace 102 of
the disclosure. FIG. 1B presents a detail view of a mesh structure
105 of an example embodiment of a fireplace screen of the
disclosure, such as the screen 100 depicted in FIG. 1A. FIG. 2
presents an exploded side view of the fireplace screen 100 and
fireplace 102 along view line 2 as depicted in FIG. 1A.
[0013] With continuing reference to FIGS. 1A and 1B, the screen 100
comprises a mesh structure 105 having through-holes 110 therein.
The mesh structure 105 is positionable about an outer surface 115
of a fireplace opening 120. The mesh structure 105 is shaped to
cover the opening 120. That is, when the screen 100 is attached, no
solid object can access the fireplace opening 120 other than
through the holes 110 in the mesh structure 105. The holes 120 in
the mesh structure 105 are configured to promote (e.g., when the
fireplace is generating heat) an inflow of air 125 external to a
fireplace 102 through the mesh structure 105 and also to promote a
vertical circulation of the air 130 across an interior planar
surface 140 of the mesh structure 105 that is located outside of
the fireplace opening 120.
[0014] The term mesh structure as used herein refers to a
semi-permeable barrier composed of an inflammable material such as
a metal, ceramic or similar material. The term mesh structure
includes solid structures having perforations to form the holes
therein, as well as strands of metal, ceramic fiber, or similar
material that are weaved or otherwise interconnected to form the
holes therein. In some cases, the mesh structure includes or is
composed of a flexible or ductile material such as steel. In some
cases, the mesh structure includes or is composed of an inflexible
material such as a ceramic.
[0015] In some embodiments of the screen 100, the mesh structure
105 is attached to a frame 145 that defines the outer surface 115
of the fireplace opening 120. The term outer surface 115 as used
herein could include other integral features of the fireplace 102
that are suitable or adaptable for attaching the mesh structure 105
thereto. In some embodiments, the fireplace opening 120 is covered
by a transparent panel 150. The transparent panel 150 can be
attached to same or different attachment points 147 of the frame
145 or other features of the fireplace 102 that the mesh structure
105 is attached to. In some cases, the mesh structure 105 can be
attached to one or more edges 155, 157 of the transparent panel
150, e.g. a glass panel, thereby locating the mesh structure 105
outside of the fireplace opening 120.
[0016] As further depicted in FIG. 2, in some embodiments of the
screen 100, one or more ends 210, 215 of the mesh structure 105 are
bent such that a central planar surface 220 of the mesh structure
105 is offset from a parallel planar surface 225 of the transparent
panel 150 when the mesh structure 105 is attached to the
transparent panel 150 or to the frame 145. In some cases, to ensure
a desired level of vertically circulating air 130, a distance 227
of the offset between the central planar surface 220 of the mesh
structure 105 and the parallel planar surface 225 of the
transparent panel 150 is at least about 1/8 of an inch, and in some
preferred embodiments, the distance 227 is a value in a range
between about 1.5 and 9 inches. In some embodiments, the mesh
structure 105 is attached to the transparent panel 150 (or to the
frame 145) such that a pull force or a push force of up to about 5
pounds does not dislodge the mesh structure from its attachment
points 147. In some embodiments, the mesh structure 105 is not
dislodged by a pull or push force up to about 50 pounds. In some
embodiments, the pull or push force (e.g., of up to 5, or, in some
cases up to 50 pounds) can be applied in any direction without
dislodging the mesh structure 105. In some cases, the mesh
structure 105 is attached and to the transparent panel 150 (or to
the frame 145), and has a limited ductility or flexibility, such
that other than its attachment points 147, a pull force or a push
force of at least 5 pounds, and in some cases up to 50 pounds, does
not cause the mesh structure 105 to contact any other structures of
the fireplace 102, including structures that are heated during the
fireplace's operation.
[0017] As also depicted in FIG. 2, in some embodiments of the
screen 100, one or more of the bent ends 210, 215 of the mesh
structure 105 forms the interior surface 140 as a beveled interior
surface that has an incident (i.e., non-perpendicular) angle to the
planar surface 225 of the transparent panel 150, or outer surface
115. For instance, in some cases, an interior angle 235 between the
interior planar beveled surface 140 and the planar surface 225 is
in a range of about 15 to 80 degrees, and in some preferred
embodiments, about 40 degrees. In addition to preventing a top
outer surface 230 from serving as a ledge upon which objects could
be placed (and thereby becoming a burn hazard when the object heats
up), beveling the surface 140 can further promote the flow of
vertically circulating air 130 thereby enhancing cooling of the
screen 100.
[0018] As additionally depicted in FIG. 2, in some cases, a bend
240 in the top end 210 of the mesh structure 105 forms a hook that
is configured to fit over an upper edge 155 of the transparent
panel so that the mesh structure 105 hangs on the transparent
panel. In some cases a bend 242 in the bottom end 215 of the mesh
structure 105 forms a clasp that is configured to fit over a bottom
edge 157 of the transparent panel 150. In some preferred
embodiments, the bends 240, 242 facilitate the tool-less removal of
the mesh structure 105 to the transparent panel 150, frame 145, or
other features of the outer surface 115.
[0019] In the some cases, in addition, or as an alternative to the
above described upper and lower bends 240, 242 there can be a bend
244 in the top or bottom end 210, 215 of the mesh 105 that forms a
flange that fits into one or more openings 165 located in an edge
(e.g., upper or lower edge 255, 257) of the fireplace frame 145
defining the fireplace opening 120. In some embodiments, the bends
244 that form flanges may fit into the same openings 165 that
flanges on the edges 155, 157 of the panel 150 fit into, to thereby
cover the opening 120.
[0020] Based on the present disclosure, one skilled in the art
would appreciate that a variety of bends or other mechanical method
could be used to facilitate the attachment of the mesh structure
105 to the transparent panel 150, the frame 145 or other features
of the outer surface 115.
[0021] In some preferred embodiments of the screen 100, the holes
110 are distributed over the entire surface 160 of the mesh 105. In
some cases, the holes 110 can be distributed uniformly over the
mesh 105. In other cases, to further promote the desired air flow
125, 130 there can be more holes 110 in certain areas of the
surface 160 (e.g., the interior planar surface 140, or the lower
1/3 of the central planar surface 220).
[0022] The amount of openness of the screen 100 is a balance
between promoting the desired air flow 125, 130 and providing the
screen 100 with sufficient mechanical strength to withstand
incidental contact without being plastically deformed or other wise
detrimentally distorted in shape. In some embodiments of the screen
100, the holes 110 in the mesh 105 occupy about 30 percent to 80
percent of a total surface area of the mesh 105. In some preferred
embodiments, the holes 110 in the mesh 105 occupy about 50 to 70
percent of a total surface area of the mesh 105.
[0023] The holes 110 can have circular, triangular, square,
rectangular or other regular shapes or irregular shapes. In some
cases, to simplify the manufacturing process, all of the holes 110
can have the same shape, while in other cases, to further promote
the desired air flow 125, 130, there can be differently shaped
holes 110 in different regions of the surface 160.
[0024] The size of the holes 110 reflects a balance of being large
enough to promote the desired air flow 125, 130 but not too large
as to permit common household objects, or human digits, to be
passed through the holes 110. In some example embodiments, such as
when the holes 110 are circular the diameter of the holes is in a
range from 3/16 to 3/8 inches. In some example embodiments, the
area of the individual holes 110 is in a range from 0.04 to 0.08
square inches. In some cases, to simplify the manufacturing
process, all of the holes 110 can have the same size, while in
other cases, to further promote the desired air flow 125, 130,
there can be differently sized holes 110 in different regions of
the surface 160.
[0025] In embodiments of the screen 100, the mesh structure 105 is
coated with a thermally insulating material 170. The insulating
material contributes to limiting the heat transfer capacity below
an acceptable level when the fireplace 102 is in operation. In some
cases, the thermally insulating material 170 can coat the entire
surface 160 of the mesh 105, while in other cases only the outside
surface 160 (i.e., the surface that would be outside of the opening
120 when attached to the outer surface 115 or to the panel 150) are
coated. Some embodiments of the insulating material 170 are
chemically resistant to common household cleaning solvents, such as
ammonia-containing or alcohol-containing cleaning solvents. Some
embodiments of the insulating material 170 are composed of
urethane-based powder coat.
[0026] Some embodiments of the screen 100 include a frameless
unitary body of the mesh structure 105. Avoiding the use of a frame
can be beneficial because a frame can deter the desired air flow
130, or, could create a hot spot on the exterior of the screen 100.
For instance, a frame itself can become a hot-spot. Nevertheless,
other embodiments of the screen 100 can include a frame around the
mesh structure 105.
[0027] FIG. 1A illustrates another embodiment of the disclosure: a
fireplace 102. The fireplace 102 comprises a housing 175 having a
base 180 and an opening 120. The fireplace 102 further comprises a
flame element 185 (e.g., a gas or propane fueled burner, or, wood
or other combustible material). The flame element 185 is located on
the base 180 and viewable through the opening 120. The fireplace
102 also comprises a fireplace screen 100. The fireplace screen 100
can include any of the embodiments of screens described above in
the context of FIGS. 1A-2. For instance, the screen 100 includes a
mesh structure 105 shaped to cover the opening 120, and holes 110
in the mesh 105 are configured to promote the inflow of air 125
external to the fireplace housing 175 through the mesh 105 and a
vertical circulation of the air 130 across an interior planar
surface 140 of the mesh 105 that is located outside of the
fireplace opening 120.
[0028] Some embodiments of the fireplace 102 include a transparent
panel 150 to which the screen 100 can be attached, as discussed
above.
[0029] In some embodiments of the fireplace 102, the screen's 102
shape, holes 110, and sometimes the insulating coating 170,
facilitate the entire outer surface 160 of the mesh 105 being below
a heat transfer capability limit when the flame element 185 is
generating heat. For instance, the limit can be indicated by the
target temperature from a thermesthesiometer evaluation according
to an ASTM standard, or other compliance temperature evaluation
protocol. For instance, in some cases the target temperature of a
thermesthesiometer reading is equal to or less than 60.degree.
C.
[0030] Another embodiment of the present disclosure is a method of
manufacturing a fireplace screen. FIG. 3 presents a flow diagram of
an example method 300 manufacture, such as methods of manufacturing
any of the screens 100 depicted in FIGS. 1A-2.
[0031] With continuing reference to FIGS. 1 and 2 throughout, the
example method 300 depicted in FIG. 3 comprises a step 310 of
forming a mesh structure 105. The mesh structure 105 is shaped to
cover a fireplace opening 120 and holes 110 in the mesh 105 are
configured to promote the inflow of air 125 external to a fireplace
102 through the mesh 105 and a vertical circulation of the air 130
across an interior planar surface 140 of the mesh 105 located
outside of the fireplace opening 120.
[0032] In some embodiments forming the mesh structure in step 310
includes a step 315 of providing a sheet (e.g., a unitary metal
sheet, such as a steel sheet in some cases), a step 320 of forming
openings in the sheet, and a step 325 of expanding the metal sheet
so as to increase a surface area of the metal sheet. As part of the
step 325 to expand the sheet, the openings in the sheet can be
expanded to form the holes 110 of mesh 105.
[0033] In some embodiments, forming the mesh structure 105 (step
310) further includes a step 330 of forming lines in a metal sheet
(in some cases, e.g., the expanded sheet produced in step 325),
and, a step 335 of bending the sheet so as to form corners along
the formed lines and a central planar surface (e.g., surface 220)
that is offset from bent ends of the expanded sheet. Forming the
lines in step 330 can include cutting, stamping, molding or any
number conventional process well known to one skilled in the
art.
[0034] Certain aspects of steps 330 and 335 are presented in FIG.
4, which shows a plan view of an example fireplace screen 100 at an
intermediate stage of manufacture. FIG. 4 presents a plan view of
an example sheet 410 after forming lines 415 in accordance with
step 330, but before bending the sheet 410 in accordance with step
335. Bending ends 420 of the sheet 410 along bend lines 425 in step
335 can produce corners along the formed lines 415. One skilled in
the art would understand how the corners could then be secured via
welding, or mechanical latching, or other bonding means.
[0035] In some embodiments, forming the mesh structure 105 (step
310) further includes a step 340 of forming notches in a sheet (in
some cases, e.g., the expanded metal sheet such as produced in step
325) and a step 345 of bending ends of the sheet along bend lines
defined by the notches so as to form hooks configured to fit over
an edge 155, 157 of a transparent panel 150 that is configured to
cover the fireplace opening 120. Any number of conventional
processes well known to one skilled in the art, such as cutting,
stamping, molding could be used to form the notches in step
340.
[0036] Aspects of steps 340 and 345 are also presented in FIG. 4.
The sheet 410 is depicted after forming notches 430, e.g., by
cutting or stamping away portions of the sheet 410. The ends 420 of
the sheet 410 can be bent along bend lines 435 that are defined by
the notches 430 so as to form hooks. Steps 340 and 345 could be
similarly used to form clasps, flanges or other structures in the
ends 240, 242 of the mesh 105 to facilitate the mesh's 105
attachment to the panel 150 or to the frame 145 of the fireplace
102.
[0037] In other embodiments, forming the mesh structure in step 310
can include a step 350 of weaving two or more metal (or ceramic, or
other material) wires together so as to form a planar lattice sheet
(e.g., a planar metal lattice sheet in some cases) with the holes
110 therein. The planar lattice sheet could then be cut and bent
such as described in steps 330-345 to form the mesh structure
105.
[0038] The some embodiments of the method 300 of forming the screen
100 can further include a step 360 of coating the mesh 105 with a
thermally insulating material. For example the mesh structure 105
can be formed in accordance with one or more of steps 330-350 and
then powder coated with a urethane based insulating material, using
procedures well known to those skilled in the art.
[0039] 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.
* * * * *