Note: Descriptions are shown in the official language in which they were submitted.
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DIRECT VENT FIREPLACE INSTALLATION
TECHNICAL FIELD
The present invention is directed to fireplace installations, and, more
particularly, direct vent fireplace units and installations.
SUMMARY
The present invention overcomes limitations of the prior art and provides
additional benefits. A brief summary of some embodiments and aspects of the
invention are presented. Thereafter, a detailed description of the illustrated
embodiments is presented, which will permit one skilled in the relevant art to
understand, make, and use aspects of the invention. One skilled in the art can
obtain
a full appreciation of aspects of the invention from the subsequent detailed
description,
read together with the figures, and from the claims, which follow the detailed
description.
Under one aspect of the invention, a gas-burning fireplace installation
assembly
is provided that is connectable to a fuel gas source. The installation
assembly
includes a furniture unit having a decorative front facing portion with an
upper portion
and a lower portion. The upper portion has an enlarged receptacle spaced above
the
ground and adapted to engage a support surface. A direct vent fireplace unit
is
positioned in the receptacle in the furniture unit's upper portion. The
fireplace unit has
an outer housing, a firebox contained in the outer housing, and a burner
assembly in
the firebox. The burner assembly is connectable to a gas line that provides
the fuel
gas from the fuel gas source. A chimney is coupled to the firebox.
Under another aspect of the invention, a fireplace installation assembly is
provided that includes a furniture unit having a lower cabinet portion and an
upper front
face portion extending from the lower cabinet portion. The upper front face
portion
having an enlarged receptacle therein. A direct vent fireplace unit is
positioned in the
receptacle in the upper front face portion of the furniture unit. The
fireplace unit has an
outer housing, a firebox contained in the outer housing, a burner assembly in
the
firebox, and a contoured surround in the firebox. The contoured surround is
spaced
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apart from the back of the firebox and is positioned between the burner
assembly and
the firebox.
Under another aspect of the invention, a wall-mounted fireplace installation
is
provided that is coupleable to a gas source. The wall structure has an
enlarged
receptacle positioned above the ground (e.g., the floor), and the receptacle
is remote
from and not surrounded by a fireplace mantle. A direct vent fireplace unit is
positioned in the receptacle in the wall structure. The fireplace. unit has an
outer
housing, a firebox contained in the outer housing, and a burner assembly in
the firebox
coupleable to the gas source. A contoured surround is positioned in the
firebox and
extends at least partially around the burner assembly between the burner
assembly
and the firebox. The surround is spaced apart from the firebox to define a
heat shield
around the burner assembly. An exhaust flue is coupled to the firebox and
extends
into a portion of the wall structure.
Under another aspect of the invention, a direct vent fireplace unit is
provided
that is positionable in an enlarged fireplace receptacle above the ground in a
furniture
unit or in a wall structure not surrounded by a mantle. The fireplace unit has
an outer
housing and a firebox contained in the outer housing. The firebox has front,
rear, and
side portions. A burner assembly is positioned in the firebox between the
front and
rear portions and is coupleable to the gas source. A surround is positioned in
the
firebox at least partially around the burner assembly between the burner
assembly and
the rear and side portions of the firebox. The surround is spaced apart from
the rear
portion of the firebox to define a heat shield around the burner assembly that
directs
heat toward the front portion of the firebox. A decorative front face is
coupled to the
outer housing and generally around the front portion of the firebox. The front
face has
height and width dimensions, the height dimension being greater than the width
dimension.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1A is a front elevation view of a direct vent fireplace unit in a
corner-
mounted furniture unit in accordance with an embodiment of the invention.
Figure 1 B is a side elevation view of one embodiment of the furniture unit
and
fireplace unit of Figure 1A.
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Figure 2 is a partial front elevation view of a direct vent fireplace unit in
a
furniture unit in accordance with an alternate embodiment of the invention.
Figure 3 is an exploded, partial front isometric view of the fireplace unit
and the
furniture unit of Figure 1 A.
Figure 4 is an enlarged isometric view of the direct vent fireplace unit of
Figure
1A shown removed from the furniture unit.
Figure 5 is an enlarged cross-sectional view of the direct vent fireplace unit
taken substantially along lines 5-5 of Figure 4.
Figure 6 is an enlarged isometric view of a contoured surround shown removed
from the fireplace unit of Figure 4.
Figure 7 is an isometric view of a wall-mounted, direct vent fireplace unit
shown
in a wall above the ground in accordance with an alternate embodiment of the
invention.
DETAILED DESCRIPTION
Gas-burning, direct vent fireplace installations in furniture units and wall
structures are described in detail herein in accordance with embodiments of
the
present invention. In the following description, numerous specific details are
discussed to provide a thorough and enabling description for embodiments of
the
invention. One skilled in the relevant art, however, will recognize that the
invention
can be practiced without one or more of the specific details. In other
instances, well-
known structures or operations are not shown, or are not described in detail
to avoid
obscuring aspects of the invention. In general, alternatives and alternate
embodiments
described herein are substantially similar to the previously described
embodiments,
and common elements are identified by the same reference numbers.
Figure 1 is a front elevation view of a furniture-mounted fireplace
installation 10
in accordance with one embodiment of the present invention. The illustrated
furniture-
mounted fireplace installation 10 includes a gas-burning fireplace unit 12
mounted in a
furniture unit 14. The fireplace unit 12 is a self-contained, direct vent
fireplace insert
coupled to a fuel gas source 16. The fireplace unit 12 is configured to
provide heat
into the room in which the fireplace installation 10 is located when the
fireplace unit is
activated, while also providing very aesthetically pleasing fire framed by the
furniture
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unit 14. The fireplace unit 12 fits seamlessly within the furniture unit 14
and provides a
very attractive addition to a room or an outside area.
The furniture unit 14 illustrated in Figure 1A is a movable corner-mounted
highboy having an upper portion 18 and a lower portion 20. The front side 22
of the
furniture unit 14 faces into a room 24 or the like, and the backside 26 is
shaped and
sized to correspond to a corner 28 of the room 24. The furniture unit '14 is
configured
to support and contain the fireplace unit 12 in the upper portion 18 above the
ground
30 and above the furniture unit's lower portion 20. It is to be understood
that the
ground 30 can be a floor, a foundation, the earth, or other support surface on
which the
furniture unit 14 is positioned. The lower portion 20 of the illustrated
furniture unit 14
includes a display area 32 for displaying selected items, such as artwork or
the like. In
alternate embodiments, the display area 32 can include multiple display areas,
shelves, drawers, doors, or other selected features for the decorative
furniture unit 14.
In one embodiment, the furniture unit 14 has full length side walls and a top
wall
that extend from the front side 22 into the corner 28. Figure 1 B is a side
elevation view
of an alternate embodiment of the fireplace installation of Figure 1A. The
front side 22
of the furniture unit 14 defines a front face extending along the upper and
lower
portions 18 and 20. The upper portion 18 has no side walls or top extending
from the
front side 22. Accordingly, the front side 22 along the upper portion forms a
false front
that receives the fireplace unit therein.
The lower portion 20 of the illustrated embodiment is a cabinet-like structure
with a substantially horizontal support surface 31 extending from the front
side 22. The
support surface 31 is positioned so a portion of the fireplace unit 12 sits on
and is
supported by the support surface. In one embodiment, the furniture unit's
lower portion
20 can have finished side walls that support the horizontal support surface
31. In other
embodiments, the lower portion 20 does not have (or need) full side walls, and
the
horizontal support surface can be supported by vertical ~ legs or fixtures
that mount to
the wall.
Figure 2 is a partial front elevation view of a direct vent fireplace unit 12
in an
alternate furniture unit 34 in accordance with an alternate embodiment of the
present
invention. The furniture unit 34 in the illustrated embodiment is a tall,
narrow,
rectangular cabinet structure configured to be positioned along a flat portion
of a wall.
The furniture unit 34 of Figure 2 also has an upper portion 18 positioned
above the
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ground (not shown) by a selected distance. The fireplace unit 12 is contained
in the
upper portion 18. In one embodiment, the fireplace unit 12 is positioned so
the middle
area .of the fireplace unit is slightly below eye level of an average adult
person
standing in the room 24. Other embodiments can have the fireplace unit 12 at
other
heights above the floor. '
While the furniture unit 14 of Figures 1A and 1 B is a corner-mounted highboy-
type structure, and the furniture unit 34 of Figure 2 is a tall, narrow
decorative cabinet,
other embodiments can include other styles of furniture units that receive the
direct
vent fireplace unit 12. As an example, the furniture unit 14 can be a
bookcase, an
entertainment center, an armoire, a cabinet, a hutch, a dresser, a storage
area, a
corner-mounted unit, a generally rectangular unit, a rounded or curved display
unit, or
the like. The furniture unit 14 can be constructed of a variety of materials;
including,
but not limited to, wood, pressboard, marble, stone, cement, metal, composite
materials, or the like.
Figure 3 is an exploded, partial isometric view of the fireplace installation
10 of
Figure 1. The furniture unit 14 of the illustrated embodiment has an enlarged
receptacle 36 in the front side 22 of the furniture unit's upper portion 18.
The
receptacle 36 is shaped and sized to receive and contain the fireplace unit
12, so the
fireplace unit is substantially surrounded and framed by the furniture unit
14. The
furniture unit 14 can include a chimney passageway 38 sized to receive a
direct vent
chimney 40 that extends from the fireplace unit 12. In the illustrated
embodiment, the
direct vent chimney 40 includes an exhaust flue 41 concentrically arranged
with an air
intake flue 42. The direct vent chimney 40 is sealably connected to a flue
adapter 44
on the top or back of the fireplace unit ~12. In an alternate embodiment, the
upper
portion 18 of the furniture unit 14 can be configured to allow for two
separate, non-
concentric flues (e.g., the exhaust flue 41 and the air intake flue 42) to be
connected to
the top or back of the fireplace unit 12. The chimney passageway 38 and the
direct
vent chimney 40 of the illustrated embodiment extend toward the top of the
furniture
unit 14, although alternate embodiments can have the chimney passageway and
the
direct vent chimney extending out the back or side of the furniture unit 14.
The furniture unit 14 can also have a fuel gas passageway 46 therein that
receives a gas line 48, which carries the fuel gas from the fuel gas source 16
to the
fireplace unit 12. The fuel gas passageway 46 and the gas line 48 can ~be
routed
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through the furniture unit 14 in a variety of locations to provide the
necessary
connection to the fireplace unit 12. In the embodiment shown in Figure 1 B
wherein the
upper portion 18 has no sides or top, the gas line 18 connects directly to the
fireplace
unit 12 without having to actually extend through the furniture unit.
Figure 4 is an enlarged isometric view of the fireplace unit 12 shown removed
from the furniture unit 14 of Figures 1A and 1 B. As best seen in Figures 3~
and 4, the
fireplace unit 12 includes a contoured outer housing 50 that fits into the
receptacle 36
in the furniture unit 14 (Figure 3). In the illustrated embodiment, the outer
housing 50
is shaped with a generally triangular back portion to correspond to the corner-
mounted
configuration of the furniture unit 14 (Figure 3). In alternate embodiments,
the outer
housing 50 can have other shapes that correspond to the desired shape relative
to the
furniture unit 14.
The outer housing 50 has an interior area that contains a firebox 52. The
firebox 52 is spaced apart from the outer housing 50 to define heat exchange
passageways 54 between the firebox and the outer housing. The heat exchange
passageways 54 are adapted to direct a flow of air around the firebox 52 so a
flow of
air moving from the room 24 through the fireplace unit 12 is heated before the
air is
blown out of the fireplace unit back into the room. The fireplace unit 12 can
include a
blower coupled to the heat exchange passageways 54 to facilitate the flow of
air
through the fireplace unit.
The firebox 52 contains a burner assembly 56, such as the Ember Fyre~ burner
assembly manufactured by Travis Industries Inc. of Kirkland, Washington. The
burner
assembly 56 is a contoured burner assembly that provides a simulated coal bed,
which
supports simulated logs and simulates a real wood burning fire, as is seen in
Figure
1A. The firebox 52 also contains a thermally insulative, semi-dome-shaped
surround
58 positioned adjacent to the burner assembly 56 so as to partially extend
around the
burner assembly. This heat shield at least partially shields the sides and
back of the
firebox from the initial heat generated by burning fuel gas at the burner
assembly 56.
Figure 5 is an enlarged cross-sectional view of the fireplace unit 12 taken
substantially along lines 5-5 of Figure 4. Figure 6 is an enlarged isometric
view of the
surround 58 shown removed from the fireplace unit 12 of Figure 4. The
illustrated
surround 58 is a contoured, arcuate member having a semi-cylindrical body
portion 60
integrally connected to a quarter-spherical top portion 62 that forms a
partial dome-like
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top structure above the burner assembly 56. Accordingly, the contoured
surround 58
defines a volume having a shape different from the shape of the interior of
the firebox
52 (Figure 5). In the illustrated embodiment, the surround 58 is self-
supporting and is
removably contained in the firebox 52. The surround 58 is set flush onto the
bottom of
the firebox 52 around the burner assembly 56 without requiring additional
mounting
brackets or structures to hold the surround in place. In other embodiments,
the
surround 58 can be fastened or otherwise secured to the firebox 52 on burner
assembly 56.
The front side of the surround 58 defines an arched opening that allows for
visibility from the front of the fireplace unit 12 into the surround's
interior area 59 and to
the burner assembly 56. The surround 58 is shaped in size so that, when a
person
looks into the firebox 52, a decorative interior surface 64 of the surround
58.around the
burner assembly 56 is visible, but side walls and back area of the firebox are
blocked
from view by the surround 58. The decorative interior surface 64 has a
selected
pattern or shape that can be any one of a variety of decorative designs. In
the
illustrated embodiment, the decorative interior surface 64 has a sculpted,
shell-type
appearance along the quarter-spherical top portion 62, and a smooth arcuate
surface
on the semi-cylindrical body portion 60. Alternate embodiments can have
decorative
interior surfaces 64 with designs that simulate bricks, tiles, or a variety of
other
decorative configurations. Other alternate embodiments can have a surround 58
with
a shape different from the illustrated semi-dome shape, while being self-
supporting, so
the surround stands up in the firebox 52 around the burner assembly 56.
In the illustrated embodiment, the surround 58 is made of a molded ceramic
material capable of withstanding the significant heat generated by the burner
assembly
56. In one embodiment, the surround 58 can be made of a material or
composition of
materials so the portions of the surround could change in color when a fire is
burning
in the firebox 52. Other embodiments can provide surrounds 58 made of other
fire-
resistant, thermally insulative materials.
As best seen in Figure 5, the contoured surround 58 is positioned between the
burner assembly 56 and the sides and back of the firebox 52. The contoured
surround
58 acts as a heat shield that directs heat forwardly toward the open front
portion of the
firebox 52. In the illustrated embodiment, the surround 58 acts as a baffle
and has
integral exhaust passageways 65 along the side portions that direct the hot
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gases from within the area of the surround back into the upper portion of the
firebox 52
and to the exhaust flue 41 of the direct vent chimney 40. Accordingly, the
surround 58
substantially increases the heat efficiency of the fireplace unit 12, and
helps keep the
back area of the firebox 52 and the backside of the outer housing 12 at cooler
temperatures. These cooler temperatures allow the fireplace unit 12 to be
mounted in
the receptacle 36 of the furniture unit 14 (Figure 3) without requiring an
excessive air
space for safety purposes.
As best seen in Figures 3 and 4, the front of the firebox 52 is open to
provide
access into the firebox, such as for maintenance of the burner assembly 56.
The open
front of the firebox 52 is sealably covered by glass 66 or the like that
allows for viewing
into the firebox when there is a fire burning at the burner assembly 56. A
plurality of
conventional controls 68 are mounted in the outer housing 50 below the firebox
52 that
allows a user to control the burner assembly 56 for operation of the fireplace
unit 12.
As best seen in Figures 1A, 1 B and 3, the fireplace unit 12 has a decorative
fireplace frame 70 mounted to the front side of the outer housing 50 (Figure
3) and
around the receptacle 36 in the furniture unit 14. The frame 70 has. an
arcuate
opening 72 positioned adjacent to the glass that allows a person to look into
the
fireplace unit 12 to see the decorative interior surface 64 of the surround
58, the burner
assembly 56, and a fire burning within the firebox 52. In the illustrated
embodiment,
the outer housing 50, the surround 58, and the frame 70 have a "portrait"
shape,
wherein the height dimensions are greater than the width dimensions. As a
result, the
tall, thin fireplace unit 12 provides an aesthetically proportioned shape
relative to the
selected furniture unit 14 to provide a very handsome fireplace installation
10.
In one embodiment, the glass 66 covering the open front of the firebox 52 is
conventional tempered, high temperature, nonglare glass. In another
embodiment, the
glass 66 has a reflective characteristic, such as a half-silvered coating,
that forms a
one-way mirror. Accordingly, when there is no fire within the fireplace unit'1-
2 and the
light in the room 24 (Figure 1A) is brighter than the light in the firebox 52,
the glass 66
provides a mirror-type reflection when looking at it from outside the firebox
(e.g., from
the room). When the burner assembly 56 is activated and a fire is started
within the
firebox 52, the light from within the firebox is greater than the light
outside of the
fireplace unit 12, so that a person can see the fire through the glass instead
of seeing
the reflection.
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Figure 7 is an isometric view of a wall-mounted fireplace installation 74 in
accordance with an alternate embodiment of the invention. This installation 74
includes a wall 76 having an enlarged receptacle 78 formed therein that
receives the
fireplace unit 12. In the illustrated embodiment, the direct vent chimney 40
is shaped
and sized to extend through or within the wall 76 so as to communicate with
outside
air. The receptacle 78 is positioned well above the floor 80 and is positioned
at a
location remote from and not surrounded by a conventional mantle of a
fireplace. In
one embodiment, the receptacle 78 and the fireplace unit 12 are positioned so
that the
middle of the firebox is roughly at eye level for an average adult standing
up.
In the illustrated embodiment, the outer housing 50 of the fireplace unit 12
and
the glass 66 are generally flush with the wall 76, and the frame ~70 is
mounted against
the wall, thereby providing the decorative frame around the glass 66 and
firebox 52,
respectively. The glass 66 can be transparent or it can be a one-way mirror,
as
discussed above. When the glass 66 is a one-way mirror, the frame 70 can have
an
appearance of being a decorative mirror frame.
The above description of illustrated embodiments of the invention is not
intended to be exhaustive or to limit the invention to the precise form
disclosed. While
specific embodiments of, and examples for, the invention are described herein
for
illustrative purposes, various equivalent modifications are possible within
the scope of
the invention, as those skilled in the relevant art will recognize. The
teachings of the
invention provided herein can be applied to other direct vent fireplace
installations, not
necessarily the particular installations described above.
While certain aspects of the invention are presented below in certain claim
forms, the inventor contemplates the various aspects of the invention in any
number of
claim forms. In general, in the following claims, the terms used should not be
construed to limit the invention to the specific embodiments disclosed in the
specification and claims, but should be construed to include all components
and
methods of manufacturing the components in accordance with the claims.
Accordingly,
the invention is not limited by the disclosure, but instead the scope of the
invention is
to be determined entirely by the claims.
From the foregoing, it will be appreciated that specific embodiments of the
invention have been described herein for purposes of illustration, but that
various
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modifications may be made without deviating from the spirit and scope of the
invention.
Accordingly, the invention is not limited except as by the appended claims.
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