U.S. patent application number 17/575003 was filed with the patent office on 2022-05-05 for modular outdoor fireplace and brick oven.
The applicant listed for this patent is Round Grove Products, LLC. Invention is credited to Scott Widmer.
Application Number | 20220136701 17/575003 |
Document ID | / |
Family ID | 1000006081061 |
Filed Date | 2022-05-05 |
United States Patent
Application |
20220136701 |
Kind Code |
A1 |
Widmer; Scott |
May 5, 2022 |
MODULAR OUTDOOR FIREPLACE AND BRICK OVEN
Abstract
A modular outdoor fireplace and brick oven system is configured
to be easily transportable and assembled. The modular system has a
chimney unit and at least one modular unit. The modular unit may be
one of an oven unit and a fireplace unit. The chimney unit and at
least one modular unit are uniquely aligned using a plurality of
alignment means. The alignment means are disposed between the
assembled units on a top surface and a bottom surface of each
modular unit and the chimney unit. The modular units are designed
to allow airflow from each modular unit to reach the chimney unit.
The modular units may further have lifting holes designed to easily
move the modular units or assembled system with a forklift, lifting
straps, and slings.
Inventors: |
Widmer; Scott; (Dalton,
OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Round Grove Products, LLC |
Dalton |
OH |
US |
|
|
Family ID: |
1000006081061 |
Appl. No.: |
17/575003 |
Filed: |
January 13, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16864460 |
May 1, 2020 |
11226104 |
|
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17575003 |
|
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62841299 |
May 1, 2019 |
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Current U.S.
Class: |
126/506 |
Current CPC
Class: |
F24B 1/189 20130101;
F24B 1/181 20130101; F24B 1/1955 20130101; F24B 7/02 20130101; F24B
1/182 20130101 |
International
Class: |
F24B 1/181 20060101
F24B001/181; F24B 7/02 20060101 F24B007/02; F24B 1/182 20060101
F24B001/182; F24B 1/195 20060101 F24B001/195; F24B 1/189 20060101
F24B001/189 |
Claims
1. A modular system, comprising: a first modular unit including a
main body with a top surface, the top surface having first
alignment means, wherein the first modular unit is at least one of
a fireplace unit and an oven unit; and a chimney unit disposed atop
the first modular unit, the chimney unit having a bottom surface
with second alignment means, the first alignment means of the first
modular unit cooperating with the second alignment means of the
chimney unit and holding the chimney unit in a predetermined
aligned position relative to the first modular unit.
2. The modular system of claim 1, further comprising a second
modular unit, the first modular unit being the oven unit and the
second modular unit being the fireplace unit.
3. The modular system of claim 2, wherein the first modular unit
has a bottom surface with third alignment means, and the second
modular unit has a top surface with fourth alignment means, the
third alignment means of the first modular unit cooperating with
the fourth alignment means of the second modular unit and holding
the first modular unit in a predetermined aligned position relative
to the second modular unit.
4. The modular system of claim 1, wherein the first alignment means
includes a first male component and the second alignment means
includes a first female component, the first female component
receiving the first male component.
5. The modular system of claim 4, wherein the first male component
is a raised elongate hollow beam.
6. The modular system of claim 5, wherein the raised elongate
hollow beam extends outwardly from the top surface of the first
modular unit by a first distance.
6. ular system of claim 6, wherein the first distance is about
3/8''.
8. The modular system of claim 4, wherein the first female
component is an elongate recess.
9. The modular system of claim 5, wherein the first modular unit
has a first modular unit frame, and the raised elongate hollow beam
is attached to a top of the first modular unit frame.
10. The modular system of claim 8, wherein the chimney unit has a
chimney unit frame, and the elongate recess is defined by a gap
between frame members at a bottom of the chimney unit frame.
11. The modular system of claim 4, wherein the first alignment
means also includes a second male component, the second male
component spaced apart from the first male component on the top
surface of the first modular unit, and the second alignment means
also includes a second female component, the second female
component spaced part from the first female component on the bottom
surface of the chimney unit.
12. The modular system of claim 1, wherein the first alignment
means and the second alignment means are oriented from a front face
of the modular system to a rear face of the modular system.
13. The modular system of claim 1, wherein the chimney unit is
disposed on the top surface of the fireplace unit.
14. The modular system of claim 1, wherein the chimney unit is
disposed on the top surface of the oven unit.
15. The modular system of claim 2, wherein the chimney unit is
disposed on the top surface of the oven unit, which is further
disposed on the top surface of the fireplace unit.
16. The modular system of claim 1, further comprising a plurality
of holes disposed in at least one of the first modular unit and the
second modular unit configured to receive at least one of
forklifts, slings, and straps for lifting and positioning the
modular unit.
17. The modular system of claim 1, wherein the first alignment
means includes a first male component and the second alignment
means includes a first female component, the first female component
receiving the first male component and the first alignment means
and the second alignment means are oriented from a front face of
the modular system to a rear face of the modular system.
18. A modular system kit comprising: a first modular unit including
a main body with a top surface, the top surface having first
alignment means, wherein the first modular unit is at least one of
a fireplace unit and an oven unit; and a chimney unit configured to
be disposed atop the first modular unit, the chimney unit having a
bottom surface with second alignment means, the first alignment
means of the first modular unit configured for cooperating with the
second alignment means of the chimney unit and holding the chimney
unit in a predetermined aligned position relative to the first
modular unit.
19. A method of forming a modular system, comprising: providing a
first modular unit including a main body with a top surface, the
top surface having first alignment means, wherein the first modular
unit is at least one of a fireplace unit and an oven unit;
providing a chimney unit configured to be disposed atop the first
modular unit, the chimney unit having a top surface with a chimney
vent formed therethrough, and a bottom surface with second
alignment means, the first alignment means of the first modular
unit configured for cooperating with the second alignment means of
the chimney unit and configured for holding the chimney unit in a
predetermined aligned position relative to the first modular unit;
applying a backerboard to the top surface of the chimney unit;
aligning the first alignment means of the first modular unit with
the second alignment means of the chimney unit; and disposing the
chimney unit on the top surface of the modular unit in the
predetermined aligned position, whereby the first alignment means
of the first modular unit cooperate with the second alignment means
of the chimney unit, thereby forming the modular system.
20. The method of claim 19, wherein the first alignment means
includes a first male component and the second alignment means
includes a first female component, the first female component
receiving the first male component.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 16/864,460, filed on May 1, 2020, which in
turn claims benefit of U.S. Provisional Patent Application Ser. No.
62/841,299, filed May 1, 2019. The entire disclosure of the above
application is hereby incorporated herein by reference.
FIELD
[0002] The present disclosure generally relates to outdoor
fireplaces and brick ovens, and more particularly, to the
configuration of outdoor fireplaces and brick ovens.
BACKGROUND
[0003] Outdoor fireplaces have become increasingly popular, either
as a landscape feature or as part of an outdoor kitchen. However,
construction of an outdoor gas fireplace is labor intensive and
consequently expensive. Typical outdoor gas fireplaces are
constructed from brick, block, or stone components, which are
custom built for each installation. Often, fireplace components
have not been constructed at a manufacturing facility, and brick or
stone veneers are normally manually applied at the jobsite.
[0004] Outdoor pizza ovens that use solid fuel (e.g. wood,
charcoal, pellets, charcoal briquettes, and coal) are also
increasingly popular. However, these outdoor brick ovens often fail
to provide adequate and consistent cooking temperatures.
Traditional brick ovens are also often large, heavy, and built-in
fixtures, for example, assembled by a skilled craftsman in the
backyard of a user. These brick ovens are not customizable once the
units are installed. The user would have to purchase a new system
should they desire additional features.
[0005] There is a continuing need for a modular outdoor fireplace
that is customizable to the needs of a user. Desirably, the modular
outdoor fireplace and brick oven is configured to be easily
transportable and assembled without requiring the intervention of a
skilled craftsman.
SUMMARY
[0006] In concordance with the instant disclosure, a modular
outdoor fireplace that is customizable to the needs of a user, and
which is configured to be easily transportable and assembled
without requiring the intervention of a skilled craftsman, has been
surprisingly discovered.
[0007] In one embodiment, a modular system has a first modular unit
and a chimney unit. The first modular unit has a main body with a
top surface. The top surface includes a first alignment means. The
first modular unit is at least one of a fireplace unit and an oven
unit. The chimney unit is disposed atop the first modular unit. The
chimney unit having a bottom surface with second alignment means.
The first alignment means of the first modular unit cooperates with
the second alignment means of the chimney unit and holds the
chimney unit in a predetermined aligned position relative to the
first modular unit.
[0008] In another embodiment, a modular system as described
hereinabove may be in the form of a kit. The kit may include a
chimney unit and a first modular unit, which are separate from each
other as provided and further include associated fastening
means.
[0009] In a further embodiment, a method for constructing a modular
system includes the step of providing a first modular unit. The
first modular unit includes a main body and a top surface. The top
surface of the first modular unit has a first alignment means. The
first modular unit at least one of a fireplace unit and an oven
unit. Then, providing a chimney unit. The chimney unit is designed
to be disposed atop the first modular unit. The chimney unit has a
bottom surface with a second alignment means. The second alignment
means of the chimney unit cooperates with the first alignment means
of the first modular unit to hold the chimney unit in a
predetermined aligned position relative to the first modular unit.
Next, selecting a location for the modular system. Afterwards,
transporting the first modular unit and the chimney unit to the
location. Then, placing the first modular unit at the location.
Next, aligning the first alignment means of the modular unit with
the second alignment means of the chimney unit. Afterwards,
disposing the chimney unit atop the modular unit in the
predetermined aligned position.
[0010] In an exemplary embodiment of the modular outdoor fireplace
and brick oven system includes a plurality of modular units, which
may include a fireplace unit, an oven unit, and a chimney unit, as
non-limiting examples. Advantageously, the various modular units
may be arranged in multiple combinations. The various arrangements
provide a consumer the ability to create a preferred outdoor
fireplace unit. Further, each of the modular units are configured
to be transported as separate pieces thus allowing for easy
transport, arrangement, and construction of the system.
[0011] Each modular unit may have a main body. The main body of
each modular unit may be defined by a framework assembly covered by
a refractory heat resistant mortar. In particular, the framework
assembly includes a framework of steel channel members, as
described further hereinbelow. The steel channel members may define
chambers within the framework assembly for the plurality of modular
units.
[0012] Each modular unit may be configured to connect to at least
one other modular unit. Advantageously, the modular units may be
arranged in any suitable location by a user. The user may include
any suitable number of modular units arranged in any suitable
layout.
[0013] The fireplace unit may include a fireplace box and a base.
The fireplace firebox may be formed from noncombustible magnesium
oxide board and refractory bricks. One of ordinary skill in the art
may select other suitable refractory materials for the fireplace
firebox, as desired.
[0014] The fireplace firebox may have a rear wall, a bottom wall,
and a pair of side walls. Each wall may be created using a
plurality of steel channel members covered by a noncombustible
board, and refractory bricks. The combination of noncombustible
board and refractory bricks may protect the steel channel members
from heat generated during combustion. The noncombustible board may
be secured to the steel channel members with fasteners such as
screws, bolts, rivets, as non-limiting examples. A skilled artisan
may select any suitable construction materials for the fireplace
firebox, as desired.
[0015] In another embodiment, the fireplace firebox may be
configured for burning wood and other suitable fireplace media. In
further embodiments, the fireplace firebox may be configured to be
connected to a gaseous fuel source. A skilled artisan may select
any suitable fireplace medium for the fireplace firebox, as
desired.
[0016] The base may be disposed beneath the fireplace firebox.
Advantageously, the base may be configured to facilitate a
transport of the fireplace unit, for example, from a location of
manufacture to the location of an end user.
[0017] The base may include a pair of holes formed in the front
wall of the fireplace unit. Advantageously, the pair of holes may
be configured to receive at least one of forklifts, slings, and
straps for lifting and positioning the fireplace unit.
[0018] In a particular example, the holes may be defined by a pair
of box-iron channels. The pair of box iron channels may be
connected to the framework assembly. In other examples (not shown),
the box-iron channels may project outwardly from the main body of
the fireplace unit to define a step. Other suitable means of
forming the holes to securely and conveniently move the fireplace
unit are also considered within the scope of the present
disclosure.
[0019] The oven unit may have a cooking chamber. The cooking
chamber may have a plurality of side walls, a cooking surface, and
a domed ceiling. The cooking chamber may be configured to burn
solid fuel, such as, wood, charcoal, pellets, charcoal briquettes,
and coal, as non-limiting examples. The cooking chamber may
facilitate the cooking of edible goods, such as pizza. A skilled
artisan may select any suitable fuel source for the cooking
chamber, as desired.
[0020] Each of the sidewalls, the cooking surface, and the domed
ceiling may be fabricated from refractory materials. The domed
ceiling may be fabricated from refractory bricks disposed in an
arch. Advantageously, the domed ceiling may trap and radiates heat
into the cooking chamber providing optimized temperatures when
cooking.
[0021] In one non-limiting example, the plurality of sidewalls and
the cooking surface may be formed from noncombustible magnesium
oxide board and refractory bricks. The noncombustible board may be
secured to the steel channel members with fasteners such as screws,
bolts, rivets, or the like. The refractory bricks may be laid atop
the noncombustible board. A skilled artisan may select any suitable
construction materials for the oven unit, as desired.
[0022] The oven unit may have a pair of holes formed in the front
wall of the oven unit. Advantageously, the pair of holes may be
configured to receive at least one of forklifts, slings, and straps
for lifting and positioning the fireplace unit.
[0023] In a particular example, the holes may be defined by a pair
of box-iron channels. Other suitable means of forming the holes to
securely and conveniently move the oven unit are also considered
within the scope of the present disclosure.
[0024] The modular outdoor fireplace and brick oven system may have
a chimney unit. The chimney unit may have a chimney flue. The
chimney flue (not shown) may be disposed in the framework assembly
of the chimney unit. Advantageously, the chimney unit may allow hot
smoke and gasses to flow from the system through the chimney unit
and away from a user of the system.
[0025] Although not specifically shown, it should be understood
that the chimney flue may include a chimney damper or flap inside
or at a top of the chimney flue, which can be adjusted manually to
allow smoke to escape or air to enter. The chimney damper may be
formed of metal or ceramic so as to tolerate the heat from the
smoke and hot gases. The chimney damper may be opened and closed
through a variety of suitable mechanisms, for example, a latch, a
pull chain, or a handle, as desired.
[0026] The chimney unit may also have a pair of holes formed the
chimney unit. Advantageously, the pair of holes may be configured
to receive at least one of forklifts, slings, and straps for
lifting and positioning the fireplace unit.
[0027] In a particular example, the holes may be defined by a pair
of box-iron channels. The pair of box iron channels may be
connected to the framework assembly. Other suitable means of
forming the holes to securely and conveniently move the chimney
unit are also considered within the scope of the present
disclosure.
[0028] In a further embodiment, the chimney unit may not include
the pair of holes for lifting the chimney unit. Advantageously, the
chimney unit without the holes for lifting provides less
obstruction and better airflow from the first modular unit such as
the fireplace unit and the oven unit.
[0029] In operation, a plurality of units of the modular outdoor
fireplace and brick oven system may be provided. The units may be
transported as separate pieces to the desired location of a user.
The user may select the desired modular units. The desired units
may be assembled according to the wants and needs of the user. The
modular units may be fastened together via screws and bolts and
corresponding apertures on the modular units. A skilled artisan may
select any suitable method for fastening the modular units, as
desired.
[0030] It should be understood that the modular outdoor fireplace
and brick oven system allows the user to customize the system to
their needs, while also facilitating transportation and assembly of
the system.
[0031] Further areas of applicability will become apparent from the
description provided herein. It should be understood that the
description and specific examples are intended for purposes of
illustration only and are not intended to limit the scope of the
present disclosure.
DRAWINGS
[0032] The above, as well as other advantages of the present
disclosure, will become readily apparent to those skilled in the
art from the following detailed description, particularly when
considered in the light of the drawings described herein.
[0033] FIG. 1 is a front perspective view of a modular outdoor
fireplace and brick oven system, according to one embodiment of the
present disclosure, and showing a chimney unit, a first modular
unit, and a second modular unit assembled, and further showing by
phantom lines underlying frame structure;
[0034] FIG. 2 is an exploded front perspective view of the modular
outdoor fireplace and brick oven system shown in FIG. 1, and
illustrating separated the chimney unit, the first modular unit
with a first alignment means, and the second modular unit with a
fourth alignment means;
[0035] FIG. 3 is a bottom perspective view of the chimney unit of
the modular outdoor fireplace and brick oven system shown in FIG.
1, further illustrating the chimney unit with a second alignment
means;
[0036] FIG. 4 is a bottom perspective view of the oven unit of the
modular outdoor fireplace and brick oven system shown in FIG. 1,
and depicting the first modular unit with a third alignment
means;
[0037] FIG. 5 is a cross-sectional side elevational view of the
modular outdoor fireplace and brick oven system taken at section
A-A in FIG. 1;
[0038] FIG. 6 is an enlarged fragmentary cross-sectional side
elevational view taken at callout B in FIG. 5, and further showing
a connector plate and a backer board connected to a steel frame of
the first modular unit and a steel frame of the second modular
unit;
[0039] FIG. 7 is a cross-sectional side elevational view of the
modular outdoor fireplace and brick oven system taken at section
line A-A in FIG. 1, with indication arrows representing a first
airflow pattern from the fireplace unit to the chimney unit and
indication arrows representing a second airflow pattern from the
oven unit to the chimney unit;
[0040] FIG. 8 is an enlarged fragmentary cross-sectional front
elevational view of the modular outdoor fireplace and brick oven
taken at section lines C-C and D-D in FIG. 5, and showing a first
alignment means of the first modular unit in communication with a
second alignment means of the chimney unit at section line C-C, and
a third alignment means of the second modular unit in communication
with a fourth alignment means of the first modular unit at section
line D-D; and
[0041] FIG. 9 is a flowchart diagram showing a method for
constructing the modular system, according to one embodiment of the
disclosure.
DETAILED DESCRIPTION
[0042] The following detailed description and appended drawings
describe and illustrate various embodiments of the invention. The
description and drawings serve to enable one skilled in the art to
make and use the invention and are not intended to limit the scope
of the invention in any manner. In respect of the methods
disclosed, the order of the steps presented is exemplary in nature,
and thus, is not necessary or critical unless otherwise
disclosed.
[0043] As shown in FIGS. 1-8, a modular system 100 includes a
chimney unit 102 and a first modular unit 104. The modular system
100 may also include a second modular unit 106 in certain
examples.
[0044] It should be understood that, within the scope of the
present disclosure, the first modular unit 104 may be one of a
fireplace unit and an oven unit, as non-limiting examples. In
particular, as shown in FIG. 1, the first modular unit 104 may be
the oven unit 104 on which the chimney unit 102 is disposed.
Additionally, the second modular unit 106 may be the fireplace unit
on which the oven unit 104 is disposed upon assembly. Although FIG.
1 shows the employment of both the fireplace unit and the oven
unit, a skilled artisan will appreciate that the modular system 100
of the present disclosure may be assembled with only the chimney
unit and one of the fireplace unit or the oven unit as the first
modular unit 104, as desired.
[0045] More particularly, and in certain embodiments (not shown),
the chimney unit 102 may be disposed on a top surface 113 of the
fireplace unit as the first modular unit 104. In other embodiments
(not shown), the chimney unit 102 may be disposed on the top
surface 113 of the oven unit as the first modular unit 104 without
a further fireplace unit. In yet another embodiment, as shown in
FIGS. 1-2, the chimney unit 102 may be disposed on the top surface
109 of the oven unit as the first modular unit 104, which is
further disposed on the top surface 113 of the fireplace unit as
the second modular unit 106.
[0046] Referring now to FIGS. 2 and 5, the first modular unit 104
has a main body 107 with a top surface 109. The main body 107 may
be manufactured from refractory or fire-resistant materials such as
metal and brick as non-limiting examples. In particular, and as
described further herein, the main body 107 may be formed from a
first modular unit frame (identified as 130 in FIG. 8). It should
be appreciated that a skilled artisan may select other suitable
fire-resistant or refractory materials to construct the main body
107, as desired.
[0047] As shown in FIGS. 2 and 8, the top surface 109 of the first
modular unit 104 has a first alignment means 110. As described
below in further detail, the first alignment means 110 is
configured to assist a user in aligning modules of the modular
system 100 during assembly. In particular examples, as also shown
in FIGS. 2 and 8, the first alignment means 110 is a first male
component. In a more specific example, the first male component is
a raised elongate hollow beam. Other suitable structure for the
first alignment means 110 may also be selected by a skilled artisan
within the scope of the present disclosure.
[0048] With continued reference to FIGS. 3 and 8, the chimney unit
102 has a bottom surface 121 with a second alignment means 122. The
second alignment means 122 is designed to cooperate with the first
alignment means 110 of the first modular unit 104. The first
alignment means 110 and the second alignment means 122 cooperate to
hold the chimney unit 102 in a predetermined aligned position
relative to the first modular unit 104 upon assembly.
[0049] It should be appreciated that the predetermined aligned
position of the first and second alignment means 110, 122 is used
to guide the assembly of the chimney unit 102 with the first
modular unit 104. Additionally, once the chimney unit 102 and the
first modular unit 104 are assembled and interlocked in the
predetermined aligned position, the first and second alignment
means 110, 122 militate against a lateral movement of the chimney
unit 102 relative to the first modular unit 104 before the chimney
unit 102 and the first modular unit 104 can be mechanically affixed
by additional means, as described further herein.
[0050] In a more particular example, the second alignment means 122
includes a first female component. The first female component is
designed to receive the first male component. In a more specific
embodiment, the first female component is an elongate recess. The
elongate recess may be further defined by a gap between frame
members at the bottom surface 121 of the chimney unit 102. It
should be appreciated that a skilled artisan may select other
suitable structures and shapes to form the second alignment means
122, as desired.
[0051] In a further embodiment, as depicted in FIG. 2, the first
alignment means 110 may also include a second male component. The
second male component is spaced apart from the first male component
on the top surface 109 of the first modular unit 104. Likewise, the
second alignment means 122 may also include a second female
component. The second female component is spaced apart from the
first female component on the bottom surface 121 of the chimney
unit 102. The second female component is designed to cooperate with
the second male component to hold the chimney unit 102 in a
predetermined aligned position relative to the first modular unit
104. It should be appreciated that a skilled artisan may use any
other number of alignment means within the scope of the
disclosure.
[0052] Referring now to FIGS. 5-8, the main body 107 of the first
modular unit 104 further has a first modular unit frame 130 formed
form a plurality of interconnected metal beams. The first alignment
means 110, for example, the raised elongate hollow beam, may be
attached to the top surface 109 of the first modular unit frame
130. In a further embodiment, the raised elongate hollow beam
extends outwardly from the top surface 109 of the first modular
unit 104 by a first distance 146. In an even more particular
embodiment, the first distance 146 is about 3/8'', which has been
found to be particularly suitable for both the alignment and
affixing the various modules of the modular system 100. One of
ordinary skill in the art may select other suitable dimensions for
the first distance 146, as desired.
[0053] In an exemplary example, shown in FIG. 8, the first
alignment means 110 is the raised elongate hollow beam formed from
a first U-shaped channel 140 and a second U-shaped channel 142. The
first U-shaped channel 140 has a first opening with a first width
W1. The second U-shaped channel 142 has a second opening and a
second width W2. The first width W1 is greater than the second
width W2. The first opening faces the second opening. The first
U-shaped channel 140 is designed to receive the second U-shaped
channel 142. The first U-shaped channel 140 is further attached to
the second U-shaped channel 142 with the use of one or more
fasteners 144. In particular, the beams of the first modular unit
frame 130 and the first and second U-shaped channels 140, 142 may
be formed from 18-gauge galvanized steel. It should be appreciated
that a skilled artisan may select other materials, dimensions, and
shapes to form and connect the first alignment means 110 to the
first modular unit frame 130, as desired.
[0054] As described hereinabove, and as illustrated in FIGS. 1-2
and 5-8, the chimney unit 102 is disposed atop the first modular
unit 104. The chimney unit 102 has a main body 127. The main body
127 may be defined by a chimney unit frame 128, for example, which
is in turn formed from a plurality of interconnected metal beams.
The main body 127 of the chimney unit 102 may be constructed from
fire-resistant or refractory materials such as metal or brick, as
non-limiting examples. An interior portion of the chimney unit 102
may further be lined with sheet metal 129, as shown in FIGS. 1 and
5. It should be appreciated that a skilled artisan may select other
suitable fire-resistant or refractory materials to construct the
chimney unit frame 128, as desired.
[0055] In certain embodiments, and as also set forth hereinabove,
the modular system 100 includes the second modular unit 106. In a
specific example, as shown in FIGS. 1-2, 5, and 7, the first
modular unit 104 is the oven unit and the second modular unit 106
is the fireplace unit.
[0056] Where the first modular unit 104 is the oven unit and the
second modular unit 106 is the fireplace unit, a top surface 113 of
the second modular unit 106 may be disposed on a bottom surface 123
of the first modular unit 104, as shown in FIGS. 2-4, and 9. In
this example, the bottom surface 123 of the first modular unit 104
has a third alignment means 124 that cooperates with a fourth
alignment means 125 on the top surface 113 of the second modular
unit 106. The third alignment means 124 and the fourth alignment
means 125 are designed to hold the first modular unit 104 in a
predetermined aligned position relative to the second modular unit
106 upon assembly.
[0057] It should be appreciated that the predetermined aligned
position of the third and fourth alignment means 124, 125 is used
to guide the assembly of the first modular unit 104 with the second
modular unit 106. Additionally, once the first modular unit 104 and
the second modular unit 106 are assembled and interlocked in the
predetermined aligned position, the third and fourth alignment
means 124, 125 militate against a lateral movement of the first
modular unit 104 relative to the second modular unit 106 before the
first modular unit 104 and the second modular unit 106 can be
mechanically affixed by additional means, as described further
herein.
[0058] In a specific embodiment, as shown in FIG. 2, the first
alignment means 110 and the second alignment means 122 are, upon
assembly, each disposed between a front face 115 of the modular
system 100 and a rear face 117 of the modular system 100. The first
and second alignment means 110, 122 are further oriented such that
ends of the first and second alignment means 110, 122 are disposed
adjacent one of the front face 115 and the rear face 117 of the
modular system. A skilled artisan may select different but suitable
placements and orientations for the first and second alignment
means 110, 122, as desired.
[0059] Referring now to FIG. 7, the modular system 100 upon
assembly includes a first airflow channel 114 and a second airflow
channel 116. The first airflow channel 114 directs heated air and
smoke from the first modular unit 104 to the chimney unit 102 in
operation. The second airflow channel 116 directs heated air and
smoke from the second modular unit 106 to the chimney unit 102 in
operation. Further, in operation the heated air and smoke from the
first airflow channel 114 and the second airflow channel 116 may be
combined within a chamber of the chimney unit 102 before being
expelled to the atmosphere through a top of the chimney unit
102.
[0060] Where the first modular unit 104 is an oven unit, the oven
unit may further have a cooking chamber 126. The cooking chamber
126 may be accessible from the front face 115 of the modular system
100. The cooking chamber 126 may include a domed ceiling. The domed
ceiling may be fabricated from refractory bricks disposed in an
arch. Advantageously, the domed ceiling may trap and radiate heat
into the cooking chamber 126 providing optimized temperatures when
cooking. One skilled in the art may select other suitable
structures for the cooking chamber 126 within the present
disclosure.
[0061] As shown in FIG. 7, the second airflow channel 116 may be
defined by a gap between a rear wall of the cooking chamber 126 and
the rear face 117 of the modular system 100. In this manner, the
second airflow channel 116 bypasses the cooking chamber 126 and the
heated air and smoke from the second unit 106 is directed directly
to the chimney unit 102.
[0062] With further reference to FIG. 7, the first airflow channel
114 directs the heated air and smoke from the first modular unit
104 to the chimney unit 102. Where the first modular unit 104 is
the oven unit, the first airflow channel 114 may be further defined
as either a hollow column or chimney pipe 116 that extends from the
cooking chamber 126 to the top surface 109 of the first modular
unit 104, for example, as shown in FIG. 2. A top of the chimney
pipe 116 is then in fluid communication with an aperture in the
bottom surface 121 of the chimney unit 102, which aperture is
aligned with the chimney pipe 116 upon assembly of the modular
system 100.
[0063] As shown in FIGS. 1-4, the chimney unit 102, the first
modular unit 104, and the second modular unit 106 are each easily
lifted and maneuvered. The lifting may be facilitated by features
that that allow for easy lifting and maneuverability. For example,
the chimney unit 102, the first modular unit 104, and the second
modular unit 106 may have a plurality of holes 108. In a specific
embodiment, the plurality of holes 108 may be constructed out of
box iron channels. The plurality of holes 108 are designed to
receive at least one of a forklift, a sling, and straps for lifting
and positioning the units of the modular system 100. It should be
appreciated that one skilled in the art may utilize other suitable
means for lifting and positioning the units of the modular system
100, within the scope of this disclosure.
[0064] In an additional embodiment, the chimney unit 102 may be
provided without a plurality of holes 108. Advantageously, the
chimney unit 102 without the plurality of holes 108 for lifting
provides less obstruction and better airflow from at least one of a
first modular unit 104 and a second modular unit 106.
[0065] It should be further appreciated that the modular system 100
may be in the form of a kit. The modular system kit may include a
first modular unit 104 and a chimney unit 102, separate from each
other as provided, and associated fastening means for connecting
the chimney unit 102 and the first modular unit 104 upon
assembly.
[0066] As detailed hereinabove, the first modular unit 104 in the
kit may be at least one of a fireplace unit and an oven unit. The
first modular unit includes the main body 107 with the top surface
109. The top surface 109 of the first modular unit 104 has the
first alignment means 110. As further explained herein, the first
alignment means 110 is configured to assist the user in aligning
the modular system 100.
[0067] The chimney unit 102 in the kit has the bottom surface 121.
The bottom surface 121 of the chimney unit 102 further has the
second alignment means 122. The first alignment means 110 of the
first modular unit 104 is configured for cooperating with the
second alignment means 122 of the chimney unit 102. The first
alignment means 110 and the second alignment means 122 are designed
to hold the chimney unit 102 in the predetermined aligned position
relative to the first modular unit 104, where the kit is
assembled.
[0068] Now referring to FIG. 9, a method 300 for constructing the
modular system 100 is shown. The method 300 includes a first step
302 of providing the first modular unit 104. A second step 304
involves providing the chimney unit 102. Next, a third step 306
includes applying a backerboard 120 to the top surface 111 of the
chimney unit 102. Then, a fourth step 308 includes aligning the
first alignment means 110 with the second alignment means 122.
Following, a fifth step 310 involves placing the chimney unit 102
on the top surface 109 of the first modular unit 104, in the
predetermined aligned position relative to the first modular unit
104.
[0069] A sixth step 312 may further include connecting the chimney
unit 102 to the first modular unit 104. As shown in FIGS. 2 and
5-7, to connect the chimney unit 102 to the first modular unit, at
least one connector plate 118 may be disposed between the chimney
unit frame 128 and the first modular unit frame 130. In a
particular embodiment, as shown in FIG. 6, at least one connector
plate 118 is disposed on the front face 115 and at least one
connector plate 118 is disposed on the rear face 117 of the modular
system 100. The at least one connector plate 118 may be attached to
the chimney unit frame 128 and the first modular unit frame 130 by
using a plurality of connector plate fasteners 134. In a specific
embodiment, the plurality of connector plate fasteners 134 may
include screws, bolts, rivets, and the like. The connector plate
118 may be formed from steel, as a non-limiting example. It should
be appreciated that a skilled artisan may select other suitable
fasteners for attaching the connector plates 118, as well as other
suitable materials for the connector plates 118, as desired.
[0070] As also shown in FIGS. 2 and 5-7, to connect the chimney
unit 102 to the first modular unit, at least one backerboard 120
must be disposed atop the at least one connector plate 118. In a
specific example, as also shown in FIG. 6, at least one backerboard
120 is disposed atop the connector plates 118 on the front face 115
and the rear face 117 of the modular system 100. The at least one
backerboard 120 may be connected to the connector plate 118 by
using a plurality of backerboard fasteners 136. In a particular
example, the plurality backerboard fasteners 136 may include
screws, bolts, rivets, and the like. The backerboards 120 may be
formed from magnesium oxide boards, as a non-limiting example, due
to their refractory properties. It should be appreciated that a
skilled artisan may select other suitable fasteners for attaching
the backerboards 120, as well as other suitable materials for the
backerboards 120 within the scope of the present disclosure.
[0071] The method 300 further includes a seventh step 314, which
includes placing the assembled modular system 100 at a desired
location. Next, in an eighth step 316, a plurality of interior
seams 148 of the modular system 100 are sealed. In a specific
embodiment, the interior seams 148 are sealed with MILL-PAC.RTM.
sealant, commercially available from IGS Industries in Meadow
Lands, Pa., USA. It should be appreciated that a one skilled in the
art may select other suitable sealants for sealing the interior
seams 148, as desired.
[0072] Additionally, as shown in FIGS. 1 and 5-7, the method 300
may include a ninth step 318 of applying a surface mortar 138 over
the assembled modular unit system 100. In a particular embodiment,
the surface mortar 138 may be further defined as a stucco material.
It should be appreciated that a skilled artisan may use other
suitable applications or materials to cover the modular unit system
100 within the scope of the present disclosure.
[0073] Advantageously, the modular system 100 and the method 300 as
described herein is useful for the construction of a modular
outdoor fireplace and oven combination. The modular system 100 and
the method 300 is customizable to the needs of the user.
Furthermore, being modular and provided as the kit for later
assembly, the modular system 100 and the method 300 is configured
to be easily transportable and assembled without requiring the
intervention of a skilled craftsman.
[0074] While certain representative embodiments and details have
been shown for purposes of illustrating the invention, it will be
apparent to those skilled in the art that various changes may be
made without departing from the scope of the disclosure, which is
further described in the following appended claims.
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