This invention relates to gas inserts designed to be retrofitted into fireplaces.
It is known to provide gas fireplace inserts that are designed to be retrofitted into wood burning fireplaces. Examples of such inserts are disclosed in U.S. Pat. No. 5,191,877 to Shimek, U.S. Pat. No. 5,752,500 to Jamieson et al., U.S. Pat. No. 6,029,655 to Hussong et al. and U.S. Pat. No. 6,116,232 to Valters et al.
The use and installation of gas fireplace inserts are constrained by certain conditions. Inserts of the sealed combustion type are often provided with an integral heat exchange passageway around the firebox into which room air is drawn in, heated and expelled back into the room. The pathway is defined by an outer wall of the insert that is spaced from the top and back walls of the firebox. Circulation of air through the pathway is often ensured by a blower mounted beneath or to the rear of the firebox. Legs or brackets supporting the firebox base provide a gap under the firebox to accommodate the gas piping and controls (and sometimes a blower) and to define the bottom part of the pathway. Heated air is exhausted forward into the room from the top of the firebox, immediately above the window of the insert.
Gas fireplace inserts should provide an aesthetically pleasing appearance. One means of doing so is to mask the gap between the insert and the inner walls of the hearth of the original fireplace. This is accomplished by providing trim designed to overlap the outer edges of the fireplace mouth (and sometimes the louvers and original fireplace facing). The trim connects to the insert such that the insert window lies generally in the plane of the fireplace mouth.
In order to provide as large a window as possible while still accommodating the outer dimensions of the insert, the insert is made as large as possible while still allowing it to be slid to the back of the hearth. As a result, there is usually very little clearance (sometimes as little as half an inch) between the top of the insert and the bottom of the lintel, baffle or smoke curtain that is provided in many wood burning fireplaces. This tight fit presents challenges to installers who are required to fit ducting or liners from the flue onto the insert's vent connector. In some cases, installers are known to remove the smoke curtain, portions of the masonry wall of the fireplace and the metal floor of manufactured fireplaces in order to install inserts. Such modifications to the fireplace stand the risk of running afoul of building codes and gas appliance restrictions.
Because of the use of trim that extends from the edges of the window of the insert to past the edges of the fireplace mouth, there is often a disproportionate amount of trim in relation to the surface area of the window. This may detract from the appearance of the fireplace by making the window look small in proportion to the overall fireplace. Various approaches are taken to minimize such effect. These include maximizing the size of the window within the constraints mentioned above, as well as providing various decorative elements and treatments to the facing. This “porthole” effect is compounded by the fact that a portion of the front area of the insert is taken up by the outlet of the heat exchange passageway, leaving less space available for the window.
As inserts are seated on the floor inside the hearth with a glass panel in the plane of the fireplace mouth, this constrains how far into the fireplace hearth the insert can be seated. This usually makes the insert look significantly shallower than the original fireplace.
It is an object of the present invention to provide a fireplace insert that offers an improved physical appearance to the installed insert. More particularly it is an object of the invention to provide an insert that looks larger, sits deeper, and is less distinguishable as an insert than the inserts of the prior art.
It is a more particular object of the invention to provide a gas fireplace insert wherein the installed insert creates the illusion of a single appliance set in an open hearth while still providing effective heating and circulation of room air.
It is a further object of the invention to provide a fireplace insert for a wood burning fireplace that is easier to install than prior art inserts, and which is easier to connect the insert vent to flue liners or ducting.
It is yet a further object of the invention to provide airflow around the fireplace insert that minimizes obstructive turbulence near the top of the insert.
These and other objects of the invention will be more fully appreciated by reference to the detailed description that follows. It will be noted that not all objects of the invention are necessarily realized in all possible embodiments of the invention as defined by each claim.
The invention consists of a gas fireplace insert assembly for insertion into a fireplace comprising a hearth with a floor, a mouth and a lintel. The insert assembly comprises a firebox having a base, a top, rear and side walls, and an outer shroud defining an heat exchange passageway surrounding the firebox for conveying air around the firebox and back into the room.
According to one aspect of the invention, the insert assembly comprises an air guide plate extending forward of the top of the passageway outlet. In a more particular aspect, the guide plate is adjustably securable to extend at various distances and angles from the top of the passageway outlet, thereby allowing the pathway outlet to be above the top edge of the fireplace mouth. This in turn allows the top edge of the insert window to be less visible from outside the fireplace.
In another aspect the guide plate comprises spaced threaded stubs, the spacing of which corresponds to spacing between slots formed in tabs extending forward of the top of the insert, said stubs being adapted to be seated in said slots.
According to another aspect of the invention, the insert comprises removable legs adapted to be removably secured to the bottom surface of the firebox. These allow the insert to be installed and then raised off the floor in the fireplace hearth such that the passageway outlet may be higher than the bottom edge of the lintel or smoke curtain, before securing the legs to the insert.
In another aspect, the top of the rear wall of the firebox is coloured a dark colour such as black while the balance of the rear wall has a lighter, contrasting colouring whereby to simulate the appearance of an open firelog basket.
In yet a further aspect, the invention comprises a gas fireplace insert and a decorative fender for installation in front of said insert, and wherein the fender is seated in front of the insert and rearwardly of the plane of the fireplace mouth.
In yet a further aspect, the invention comprises a fireplace comprising a fireplace hearth with a floor, a gas fireplace insert seated on said hearth floor, at least one vent extending from the firebox of the insert to the exterior of the fireplace and wherein the space between the gas fireplace insert and the interior walls of the hearth function as a passageway for drawing in room air, circulating said room air around the gas fireplace insert and expelling said room air back into the room.
In yet a further aspect, the fireplace according to the invention includes a gas fireplace insert that has a front window with a transparent panel therein, said panel being in a plane that is spaced rearwardly from the plane of the mouth of the fireplace, the panel extending upwards at least to within 2 inches of the lintel.
In a further aspect of the fireplace according to the invention, the fireplace hearth has a rear wall that is painted black, and portions of said rear wall are visible from the front of the fireplace.
In yet a further aspect, the invention comprises a fireplace including an insert with removable legs on the base thereof, means for connecting a guide plate to the top of the insert, a guide plate extending from the top of the insert forward to the front of the top edge of the fireplace mouth, the insert being seated into the fireplace such that the window of the insert lies in a plane that is rearwardly offset in relation to the plane of the fireplace mouth, and a fender seated on the fireplace hearth and set back into the fireplace. The top edge of the insert window is located within 2 inches of the top edge of the fireplace mouth. The top portion of the rear wall of the insert firebox is coloured a darker colour such as black and room air has substantially unimpeded access to the sides of the insert.
In another aspect the invention comprises a method of installing a fireplace insert comprising the steps of removing removable legs from the base of the insert, sliding the insert into the hearth such that the plane of the insert window is spaced rearwardly from the plane of the fireplace mouth, connecting liners to the insert, raising the insert into the fireplace and re-installing the legs, and installing a guide plate between the top of the insert and the top of the fireplace mouth. In a further aspect, a fender is also disposed on the hearth floor in front of the insert and rearwardly of the plane of the fireplace mouth.
In another aspect, the invention comprises a gas fireplace insert assembly, comprising a firebox having a base and legs adapted to be removably secured to said base.
In a further aspect, the firebox comprises a top and at least one wall, the wall extends between the top and the base such that the base, the top and the at least one wall define a front-opening firebox; the wall has a rear portion and side portions having a dark colour and a contrasting light colour, the light colour extends downward from a demarcation between the dark and light colours to the base; and the demarcation is continuous across the rear and side portions. In yet a further aspect, the at least one wall comprises a rear wall and opposed side walls.
In a further aspect, the top and base each have inner surfaces facing the interior of the firebox and outer surfaces, and the dark colour is applied to the inner surfaces, to the outer surfaces, to the legs and to an outer surface of the wall.
In another aspect, the invention comprises a gas fireplace insert assembly with a decorative fender having a width of at least the distance between the opposed side walls of the assembly.
In further aspect, the invention comprises a gas fireplace insert assembly with a heat exchange passageway for conducting air from the vicinity of the base and along at least one outer wall of the firebox, and having an outlet defined between the top and a top panel mounted in spaced relationship to the top; a guide plate for guiding in a forward direction air exiting the outlet, where the guide plate is removably attached to said top panel; and a decorative fender having a width of at least the distance between opposed side walls of the assembly.
In a further aspect, the top panel comprises one or more forwardly extending tabs and the guide plate is adapted to be removably attached to said tabs. In yet a further aspect, the guide plate comprises one or more downwardly extending stubs, each of which is adapted to be removably attached to one of the forwardly extending tabs; and each of the one or more downwardly extending stubs may be spaced from a longitudinal centreline of the guide plate.
In another aspect, the invention comprises a gas fireplace insert assembly comprising a firebox having a base, opposed side walls and a top; legs adapted to be removably attached to the firebox base; a heat exchange passageway for conducting air from the vicinity of the base and along at least one outer wall of the firebox, and having an outlet defined between the top and a top panel mounted in spaced relationship to the top; and a guide plate for guiding in a forward direction air exiting the outlet, the guide plate being removably attached to the top panel.
In another aspect, the invention comprises a gas fireplace insert assembly comprising a firebox having a base, opposed side walls and a top; a heat exchange passageway for conducting air from the vicinity of the base and along at least one outer wall of the firebox, and having an outlet defined between the top and a top panel mounted in spaced relationship to the top; and a guide plate for guiding in a forward direction air exiting the outlet, the guide plate being removably attached to said top panel. In a further aspect, the gas fireplace insert assembly may comprise legs adapted to be removably attached to the firebox base.
In another aspect, the invention comprises a fireplace comprising a hearth having a floor, a mouth and a lintel and further comprising a gas fireplace insert assembly resting on the floor, where the insert assembly comprises a base, a top and at least one wall extending between the base and the top and legs adapted to be removably secured to said base; where the top extends above the height of the lintel.
In a further aspect, the invention comprises a fireplace with a heat exchange passageway for conducting air from the vicinity of the base and along at least one outer wall of the firebox, and having an outlet defined between the top and a top panel mounted in spaced relationship to the top and a guide plate for guiding in a forward direction air exiting the outlet, the guide plate being removably attached to said top panel.
In yet a further aspect, the invention comprises a fireplace with at least two contrasting colours inside the insert assembly; and a dark colour applied to the inside of the hearth. The contrasting colours may comprise a dark colour and a light colour. In yet a further aspect, the wall of the insert assembly may have a rear portion and side portions having a dark colour and a contrasting light colour, the light colour extending downward from a demarcation between the dark and light colours to the base; and the demarcation being continuous across said rear and said side portions. In yet a further aspect, the dark colour may be further applied to the legs and to all outer surfaces of the insert assembly.
In a further aspect, the fireplace may comprise a decorative fender inside the hearth, between the insert assembly and the mouth. The decorative fender may be unsupported by the insert assembly.
In another aspect, the invention comprises a method of installing a gas fireplace insert assembly in a fireplace having a rear wall, a hearth having a floor, a mouth and one or more ducts, comprising the steps of placing a gas fireplace insert onto the floor through the front opening; connecting the insert to the one or more ducts; and attaching one or more supports to an underside of the insert, thereby lifting the insert away from the floor.
In a further aspect, the method of the invention may comprise installing a gas fireplace insert assembly, wherein the insert further comprises a firebox having a base, a top and a heat exchange passageway for conducting air from the vicinity of the base and along at least one outer wall of the firebox, the heat exchange passageway having an outlet defined between the top and a top panel mounted in spaced relationship to the top, and the method may further comprise the step of attaching to the top panel a guide plate for guiding in a forward direction air exiting the outlet, the guide plate being removably attachable to the top panel.
In yet a further aspect, the method of the invention further comprises the step of placing a decorative fender on the floor of the fireplace between the insert and the mouth.
Other aspects of the invention will be appreciated by reference to the detailed description of the preferred embodiment and to the claims.
The preferred embodiment of the invention will be described by reference to the attached drawings in which:
Referring to
Insert 12 includes a firebox, a burner assembly, a shroud partially surrounding the firebox and a heat exchange passageway, as described below. A log set 150 (seen only in
Referring to
A burner assembly is seated on base rim 20 and includes a burner plate 56, a burner 32, a pilot assembly 34 and a control and fittings assembly 36. A window and glass panel 38 are fitted to the front of the insert 12.
Referring to
A gap 54 at the forward edge of the top shroud panel 48 defines the passageway outlet. In use, room air is drawn under the burner plate 56 as indicated by arrow 57, through the gaps 50, 52 and 53, up the sides 58, 60 and rear 62 portions of the passageway 40 and across the top 64 of the passageway 40. The heated air is exhausted out of the outlet 54 between the top shroud panel 48 and the firebox cover 31. A blower (not shown) may optionally be seated beneath the firebox to draw room air under the base and into the heat exchange passageway. In the absence of a blower, natural convection will draw sufficient room air into the passageway 40.
Referring now to
As best seen in
Guide plate 14 is illustrated in
As best illustrated in
Referring to
As best shown in
A decorative fender 16 is provided with suitable means 122 allowing the fender 16 to be positioned as a freestanding unit on the floor 99 of the fireplace hearth 98 in front of the insert 12. Fender 16 is preferably made to resemble a protective fender used in an open hearth fireplace. Fender 16 generally has a width of at least the distance between the opposed side walls 24, 26.
The installation of the fireplace insert assembly according to the invention will now be described with references to
Prior to seating the insert assembly 10 into the fireplace hearth 98, legs 100, 102 are removed from the insert assembly 10. The insert assembly 10 is then slid rearwardly through fireplace mouth 95, along the hearth floor 99 and as far back as possible into the hearth 98. It is no longer necessary to align the front panel of the insert assembly 10 with the mouth 95, as is required in the prior art.
With the legs 100, 102 removed and the insert assembly 10 seated and set back on the floor 99 of the hearth 98, there is sufficient space above the insert assembly 10 to enable the installer to connect the exhaust and combustion air liners 66, 68 to the collars 35 and 79 respectively, without the need for sophisticated vent engagement systems. The clearance provided by the insert assembly 10 and the position of the insert assembly 10 in the fireplace make access to the liners and their connection to the insert assembly 10 considerably easier than in the prior art.
Once the liners are connected to the insert assembly 10, the insert assembly 10 is then raised off the floor 99 of the hearth 98 and legs 100, 102 are re-installed on the base of the insert assembly 10 using appropriate fasteners.
The guide plate 14 is installed by first loosely engaging wing nuts 88, 90 onto stubs 84, 86. The guide plate 14 is then angled past the top edge 94 of the fireplace mouth 95 and stubs 84, 86 are engaged into slots 80, 82 of tabs 76, 78 such that tabs 76, 78 are sandwiched between the wing nuts 88, 90 and the guide plate 14. The guide plate 14 is then extended forward to contact, or nearly contact, the front of the fireplace and the wing nuts 88, 90 are tightened.
The guide plate 14 ensures that air exhausted from the heat exchange passageway outlet 54 will be directed to the fireplace mouth 95 with minimal turbulence being generated atop the insert 10. This arrangement promotes the smooth flow of air back into the room resulting in increased efficiency.
Fender 16 is then installed in front of the insert assembly 10, but is placed as far back into the hearth 98 as possible. The ability to set back the fender 16 on the floor 99 of the hearth 98 is the result of the ability to set back the insert assembly 10 itself into the fireplace mouth 95. This in turn is the result of using the guide plate 14, which overcomes the turbulence effects that would otherwise be suffered from seating the insert assembly 10 too far back into the fireplace mouth 95.
No additional facing or trim is required around the edges of the insert assembly 10 or of the fireplace mouth 95. The absence of trim and the setting back of the insert assembly 10 and fender 16 into the fireplace hearth 98 enhances the effect of a stand-alone grate and log set 150 seated in a fireplace enclosure.
Colouring the upper portion 146 of at least one of the firebox side walls 24, 26, rear wall 22 and baffle 30 a darker colour, such as black, while providing a contrasting lighter coloured lower portion 148 surrounding the log set 150 can further enhance such effect. In an embodiment best shown in
The inner surfaces of the hearth 98 may also be coloured a dark colour, similar to the dark colour on the insert assembly 10, further camouflaging the edges of the insert assembly 10 and providing the illusion of a larger, deeper hearth 98.
In another embodiment, more parts of the insert assembly 10, except the lighter coloured portion 148, may also be a dark colour. This may include the outer surfaces of the base rim 20, rear wall 22, side walls 24, 26, firebox top 28 and legs 100, 102, to ensure no outer part of the insert assembly 10 is visible in the darkness of the hearth 98
The insert assembly 10 according to the invention may include a window that is larger than the prior art inserts and whose top edge is hidden behind the top edge of the fireplace mouth 95, further masking the frame of the insert 10.
As the invention obviates the need for trim between the insert assembly 10 and the fireplace mouth edges, a freer flow of room air around the insert is made possible. Despite seating the insert assembly 10 as far back as possible within the fireplace hearth, there will typically be space for room air to be drawn in around the sides of the insert, in addition to any room air entrained into the heat exchange passageway. Such air will be drawn principally by convection but some of the air may be incidentally entrained towards the sides of the insert as a result of the operation of a blower which otherwise seeks to entrain air into the heat exchange passageway. The air then proceeds by convection up the sides and back of the insert and will find its way around guide plate 14. As a result, the room air will undergo secondary heat exchange from contact with the exterior walls and panels of the insert, thereby further heating the room.
The invention therefore achieves the objects of an insert having a significantly improved visual appearance when seated in a fireplace. The insert is also easy to install and provides an efficient heat exchange with the room air.
It will be appreciated that while the preferred embodiment of the invention has been described, other variations may be practised within the scope thereof without departing from the principles of the invention.