Patent Application
20250020330
The presently disclosed embodiments relate generally to electric fireplaces. More particularly, the presently disclosed embodiments relate to a method for assembling an electric fireplace to improve shipping efficiency and reduce costs.
Electric fireplaces are indoor consumer products that include an electric heater for providing heat, and an artificial log and fire to simulate the effects of a fire. Together, the electric fireplace provides heat and “fire” to a user much like a conventional fireplace but without a burning flame or combustion of fuel.
The process of manufacturing an electric fireplace has changed over the years. Conventional manufacturing processes involved shipping pre-assembled fireplace inserts, which often required larger packaging and resulted in higher shipping costs. The size and weight of the fully assembled inserts contributed to these challenges, making it difficult to optimize shipping logistics and cost-effectiveness. As a result, there is a growing demand for alternative assembly methods that allow for more compact packaging and simplified shipping.
In an attempt to address these challenges, U.S. Pat. No. 11,619,391 proposed a solution by selling electric fireplaces without pre-assembled inserts. Instead, this patent disclosed a process where the fireplace cabinet panels, heater, and logs are shipped together in a single package. The user would then assemble the cabinet and independently install the heater and logs. While this method offered potential benefits in terms of compact packaging and reduced shipping costs, it introduced certain drawbacks.
One of the drawbacks of the method described in U.S. Pat. No. 11,619,391 is the resulting electric fireplace's reduced structural stability compared to fireplaces with pre-assembled inserts. The absence of an insert that is specifically designed to fit and support the fireplace components within the cabinet may lead to potential structural weaknesses, potentially compromising the overall integrity of the fireplace.
Furthermore, the user experience aspect is a crucial consideration in the design and assembly of electric fireplaces. Installing a fully-assembled insert into the fireplace cabinet is not only more straightforward but also provides for easier service and maintenance of the insert by not requiring the end user to disassemble the fireplace cabinet during maintenance or servicing of the insert. The act of seeing the project “come together” by placing the insert into the cabinet creates a more fulfilling experience for the end-user.
Therefore, there is a need for an improved method for assembling electric fireplaces that addresses the challenges of compact packaging, shipping costs, structural stability, and user satisfaction. The present invention aims to fulfill this need by providing a novel method that combines the benefits of pre-assembled inserts with efficient packaging and shipping, resulting in a structurally stable and user-friendly electric fireplace assembly process.
The presently disclosed embodiments overcome the drawbacks of the prior art by providing the components of an electric fireplace with insert, while also packaging the components in a compact manner so as to reduce shipping costs and issues. For example, the present invention includes a method of assembling an electric fireplace including providing the structural components of an insert cabinet, providing the functional components of an insert cabinet including at least logs and a heater, providing the structural components of a fireplace cabinet, assembling the insert including assembling the structural components of the insert cabinet and further including installing the functional components of the insert into the insert cabinet, and installing the insert into the fireplace cabinet.
The presently disclosed embodiment further include a method of packaging and shipping an electric fireplace assembly. This method includes providing parts of an insert for the electric fireplace comprising structural components and functional components, providing parts of a fireplace cabinet including structural components of the fireplace cabinet, shipping the structural components of the insert and the structural components of the fireplace cabinet in disassembled form, and providing instructions to a user for assembling the insert and installing the insert into the fireplace cabinet.
For the purpose of facilitating an understanding of the subject matter sought to be protected, there are illustrated in the accompanying drawings embodiments thereof, from an inspection of which, when considered in connection with the following description, the subject matter sought to be protected, its construction and operation, and many of its advantages should be readily understood and appreciated.
While this invention is susceptible of embodiments in many different forms, there is shown in the drawings, and will herein be described in detail, a preferred embodiment of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to embodiments illustrated. As used herein, the term “present invention” is not intended to limit the scope of the claimed invention and is instead a term used to discuss exemplary embodiments of the invention for explanatory purposes only.
Disclosed is a method of assembling an electric fireplace that achieves compact shipping but also allows the insertion of a fireplace insert. The method includes providing the structural and functional components of an insert cabinet, providing the structural components of a fireplace cabinet, and assembling the fireplace cabinet and insert cabinet separately. The method further includes instructions for having the user install the insert into the cabinet to achieve the fully assembled electric fireplace.
Next, the top panel 130 is installed between the right 120 and left 125 panels, positioned above the bottom panel 115, logs 105, and grate 110. A back panel 135 is installed at the rear of the insert 100, enclosing the interior of the insert 100. The back panel 135 may feature a cord aperture 137, allowing electric power cords to enter and exit the interior of the insert 100. The front panel 140 is then installed at the front of the insert 100, providing a finished appearance and providing a partial or full enclosure of the logs 105 and grate 110. For example, the front panel 140 can be made of glass, tempered glass, clear plastic, or any other material that permits transparent or semi-transparent viewing of the logs 105 and grate 110. Alternatively, the front panel 140 need not be transparent or semi-transparent. Together, the panels 115, 120, 125, 130, and 135 comprise an insert cabinet 150 and make up the structural components of the insert 100. One or more of the logs 105, grate 110, and heater 145 make up the functional components of the insert 100, either alone or in combination.
The top panel 130 enhances the structural stability of the assembly while also serving as the base for installing the heater 145. The heater 145 is installed on top of the top panel 130, providing the essential heat source for the electric fireplace. The heater 145 is securely attached and positioned to emit heat effectively while remaining safely contained within the insert cabinet 150.
The assembly process of the second embodiment is similar to the first embodiment, with certain modifications to enhance packaging configurations and stability during shipping. The right 327 and left 328 braces, and the lower brace 329, are introduced to allow the right 320, left 325, and bottom 315 panels to be split, facilitating a greater number of packaging configurations. This enables larger inserts 300 to be divided into more pieces, reducing the likelihood of breakage during shipping.
Moreover, the right 327 and left 328 braces and the lower brace 329 can also contribute to stabilizing the back panel 335. In some embodiments, the braces 327, 328, 329 may be made of a different material than the other panels, such as a reinforced material or a thicker material. Alternatively, the braces 327, 328, 329 may be reinforced with metal or another suitable material. The differential material or reinforced design provides added strength and rigidity to the insert 300, further enhancing the overall structural stability of the insert 300.
The remaining elements and their interconnections in the second embodiment follow a similar configuration and sequence as described in the first embodiment. The logs 305 are positioned within the grate 310, which is placed on the bottom panel 315. The right 320 and left 325 panels are coupled to the bottom panel 315 and the top panel 330 is installed between them, securing the insert cabinet 350 in a vertical direction.
The back panel 335 is attached at the rear of the insert cabinet 350 and incorporates the cord aperture 337 to allow for the passage of electric power cords. The front panel 340 is installed at the front of the insert cabinet 350 to partially or fully enclose the insert cabinet 350. Finally, the heater 345 is positioned on top of the top panel 330, providing the necessary heat source for the electric fireplace. The heater 345 is securely attached, ensuring efficient heat distribution and safe operation.
By incorporating the right 327 and left 328 braces and the lower brace 329, the second embodiment of the insert 300 allows for improved packaging configurations, reducing the risk of breakage during shipping. The additional stability provided by the braces 327, 328, 329, whether through differential material, reinforcement, or increased thickness, further enhances the overall structural integrity of the insert 300. The resulting electric fireplace provides versatility in packaging, while ensuring reliable performance and user satisfaction.
The assembly process of the third embodiment retains the use of the right and left braces 527, 528 as in the second embodiment. However, in this embodiment, the lower brace 329 is omitted, and a single bottom panel 515 is utilized instead. This modification allows for greater flexibility in packing the insert during shipping. By incorporating split side panels and a larger bottom panel, various packaging configurations can be achieved to accommodate different insert sizes and reduce the risk of breakage during transportation.
Similar to the previous embodiments, the side braces 527, 528 play a role in stabilizing the insert cabinet 550. By utilizing braces made of differential materials, reinforced materials, or by adjusting their thickness or size, the back panel's stability and overall structural integrity can be enhanced, ensuring a secure and reliable electric fireplace assembly.
By omitting the lower brace and incorporating a single bottom panel, the third embodiment of the electric fireplace assembly provides greater flexibility in packaging configurations while maintaining stability during shipping. The inclusion of side braces aids in stabilizing the back panel, thereby reinforcing the overall structural integrity of the fireplace assembly. The resulting electric fireplace offers improved packing options, reliable performance, and user satisfaction.
The method 800 then proceeds to step 820, where the structural components of the fireplace cabinet 155 are provided. These components can include panels similar to those of the insert 100, but that can be used to assemble together the fireplace cabinet 155 in a similar manner. The insert 100 is then assembled in step 825, and the insert 100 is then installed in the fireplace cabinet 155 in step 830.
The insert 100 is fully assembled when it is installed in the fireplace cabinet 155 in step 830. By allowing this, the method 800 allows for a more structurally stable insert 100 as compared to the prior art, which supports the heater and logs through a conventional cabinet that lacks an insert. By comparison, the insert 100 can absorb stresses without such stresses impacting the fireplace cabinet 155, and can therefore better support the logs 105 and grate 110. At the same time, by shipping the structural components of the insert 100 disassembled, the insert 100 can be assembled by the user after shipping and the structural components can be more efficiently packed during the shipping process. This reduces the expense and complexity of shipping the structural components of the insert 100 as a fully assembled item. Further, by permitting the user to assemble the insert 100 as one piece, the user achieves the satisfaction of completing the assembly of the electric fireplace and allows maintenance of the fireplace without complete disassembly.
Various structural components are defined within the presently disclosed embodiments. These structural components can be coupled together during installation or assembly in any manner, including by fasteners, adhesives, or a friction fit. For example, the structural components can be coupled together by screws, nails, bolts, tabs, glue, cement, welds, interference fits, a ball detent system, or any other mechanism that causes the permanent, semi-permanent, or temporary attachment of one object to another.
The structural components can be any material, but in an embodiment are made of particle board, plywood, plastic, solid wood, metal, or any combination of the above, or any other suitable structural material.
The heater 145 can be a conventional electric air heater, or can be any other heater such as a gas heater.
As used herein, the term “coupled” and its functional equivalents are not intended to necessarily be limited to direct, mechanical coupling of two or more components. Instead, the term “coupled” and its functional equivalents are intended to mean any direct or indirect mechanical, electrical, or chemical connection between two or more objects, features, work pieces, and/or environmental matter. “Coupled” is also intended to mean, in some examples, one object being integral with another object.
The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. While particular embodiments have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made without departing from the broader aspects of the inventors' contribution. The actual scope of the protection sought is intended to be defined in the following claims when viewed in their proper perspective based on the prior art.
