Open ended molded fireplace box and method

Abstract

A prefabricated open-ended fireplace box for use in fireplace assemblies is molded from a slurry of refractory ceramic fibers and a non-organic binder. The prefabricated fireplace box is preferably formed in or over a mold which provides an accurate shape to the green or semi-rigid open end box which must be dried or partially fired while on the mold to avoid warping or distortion while being removed from the mold. A rigid surround trim in the form of a C-shape is placed in or on the mold at the open ends of the fireplace box. At least one attachment flange of the surround trim is integrally molded into walls of the fireplace box so that at least the open end of the semi-rigid fireplace box is made rigid when removed from the mold.

Description

FIELD OF THE INVENTION

This invention relates generally to prefabricated fireplaces, and more particularly to a prefabricated fireplace assembly that is peripherally framed with standard building materials for direct installation into a rough opening in a building. More particularly the present continuation invention relates to prefabricated open ended fireplace boxes for installation in new or existing homes.

BACKGROUND OF THE INVENTION

Whether for providing heat, for purely decorative purposes, or for value enhancement, fireplace assemblies have become commonplace in today's building trades for both residential and commercial applications. Most new home construction designs include at least one, and often several fireplaces. Further, a significant number of remodeling projects are focused about fireplace assemblies.

Such popularity is in great measure due to the development of direct vented fireplace assemblies, of the type generally described in U.S. Pat. No. 4,793,322. By eliminating the need for a conventional chimney, the direct vented fireplace assembly not only drastically reduces the cost of installing a fireplace, but also significantly increases the architectural design flexibility for such units, since the fireplace assemblies can now be designed in numerous configurations and can be readily positioned virtually anywhere in a room or building. More recent use of light weight reinforced ceramic fiber materials and binders has enabled fireplace fireboxes and combustion chambers to be constructed with the appearance of traditional masonry fireplaces, while exhibiting superior insulating properties that enables such assemblies to be installed with minimal separation spacing from surrounding building materials. The cross-referenced copending patent applications U.S. Pat. Nos. 09/024,285 and 08/538,866 describe such fireplace construction techniques and are herein incorporated by reference to the extent that their disclosures are useful or necessary for understanding and/or supporting this invention.

Heretofore, fireplace assemblies of the type that are inserted into a wall have generally required the contractor to not only frame in an enclosure for receiving the assembly, but to also prefinish that enclosure with sheetrock or other appropriate fire-grade material, prior to installation of the fireplace assembly. Further, the fireplace assemblies inserted into such enclosures typically include a metal protective outer shroud material. Such construction processes and fireplace construction both increase the overall cost of the project.

The present invention addresses the above short comings of prior fireplace assemblies and installation requirements. The present invention provides a novel fireplace assembly construction that eliminates the need for contractor construction of prefinished receptor enclosures, as well as the need for costly outer sheet metal fireplace assembly shrouds and provides other benefits to the installing contractor.

SUMMARY OF THE INVENTION

The present invention related to a low cost prefabricated fireplace box for use in fireplace assemblies and provides a highly accurate distortion free mounting face and surround trim that reduces the cost of manufacture as well as the cost of installation into fireplace assemblies.

The present invention incorporated the most desirable features and advantages of prior fireplace assembly designs, while reducing the costs of both the fireplace assembly and its preinstallation construction labor and materials. The present invention provides a fireplace assembly that requires only a rough opening in the wall in which the fireplace will be mounted, similar to that for a window or similar fenestration, for mounting the assembly. No labor intensive enclosure construction or prefinishing is required to contain the fireplace assembly. The assembly can simply be inserted into the presized rough opening and affixed thereto by brackets extending from the assembly, all during the framing phase of a building project.

The factory produced fireplace assembly is delivered to the jobsite with a preassembled external framework of building materials. The framework also serves as the shipping carton for the assembly. Once the contractor hangs the assembled unit in the rough opening, he can directly apply sheetrock or other interior wall materials up to the assembly at the same time that the interior walls of the building are being finished, and can directly apply external siding or other wall and/or roof canopy materials to or against the factory provided framework of the fireplace assembly. Contractor installation error is virtually eliminated, since proper safety and reliability concerns are addressed at the factory, not at the jobsite, by the preinstallation of surrounding framing members of known strengths and clearance tolerances to satisfy all structural, governmental and safety requirements for the fireplace assembly.

According to one aspect of the invention there is provided a prefabricated fireplace assembly, comprising: (a) a fireplace box defining a combustion chamber; and (b) a framework of building materials connected to operatively support the fireplace box, wherein the framework forms an integral part of the fireplace assembly that remains connected to the fireplace assembly when it is installed within the building structure. The framework assembly is of a configuration that can be directly mounted within a rough opening of a wall in a building structure by mounting flanges.

According to the principal aspect of the present invention, there is provided a universal fireplace box that may be injection or vacuum molded according to teachings set forth in our U.S. Pat. No. 5,941,237 and further includes a rigid surround trim frame and/or an exhaust outlet collar, both of which include attachment flanges integrally molded into the fireplace box so that open ended box may be removed from its mold in a semi-rigid state before final drying and/or firing.

According to another principal aspect of the present invention a highly accurate rigid C-shaped surround trim open frame is integrally molded into the open ends of an open ended fireplace box which give accuracy and stability to the fireplace box and comprises a reference frame for mounting fireplace components or installing fireplaces in houses. According to a further aspect of the invention, the fireplace box preferably comprises a ceramic combustion chamber of molded construction and having a support flange integrally embedded within the ceramic for securing the fireplace box to the framework. According to yet a further aspect of the invention, the framework is configured to become a part of an external wall of the building structure in which the fireplace assembly is to be installed.

According to yet a further aspect of the invention there is provided a prefabricated fireplace assembly module of a type suitable for zero tolerance installation within a rough opening of a building framework, wherein heat generated by use of the fireplace assembly will not reach predetermined unsafe levels for the building framework, comprising: (a) an external framework of building materials of a type directly compatible and configured for mounting to the rough opening building framework; and (b) an open fireplace box fixedly mounted to and carried by said external framework and bordered by said external framework on at least three sides of said fireplace box.

According to yet a further aspect of the invention there is provided a method of manufacturing a prefabricated fireplace assembly comprising the steps of: (a) forming a fireplace box having a combustion chamber; (b) forming a framework of building materials about said fireplace box; and (c) mounting the fireplace box to the framework, wherein the fireplace box and framework collectively form a prefabricated fireplace assembly module.

While specific venting configurations will be illustrated in describing preferred embodiments of the invention, it will be understood by those skilled in the art that the invention is not to be limited to any particular vent configuration. As a matter of fact, the principles of the invention could apply equally well to a totally ventless firebox construction. Further, while the present invention will be illustrated with reference to several specific examples of framing configurations applied to the fireplace assembly, the particular framing configuration or shapes illustrated in the preferred embodiment is not intended to be limiting to the invention. Also, framing materials need not be applied to all sides of the fireplace, but need only apply to those sides of the fireplace that would be covered by finishing materials. For example a corner or three-sided fireplace unit would require less framing materials. It will also be appreciated that while the preferred embodiments of the invention have been described with respect to wooden framing building materials, the invention is not limited to the use of any particular type of building materials. For example, the wooden framing materials could be replaced by plastic or metal or other suitable building materials.

It will also be understood that while a gas energized assembly will be described with respect to the preferred embodiments, the invention is not limited to gas-fired units, but could equally apply to wood burning structures. Further, while the present invention will be described with respect to its use with a universal firebox of molded RFC material, the invention is not to be limited to any particular RCF material, and can be used with other known firebox construction such as those of sheet metal and other known materials. These and other modifications of the invention will be understood by those skilled in the art in view of the following description of the invention, with reference to specific preferred embodiments thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring to the figures, wherein like numerals represent like parts throughout the several views:

FIG. 1 is a schematic cross-sectional drawing in side elevation of a prior art direct vented fireplace unit having a metal combustion chamber surrounded by an outer housing preformed from formed panels of sheet metal, and illustrated as it would appear as mounted in a typical enclosure;

FIG. 2 is a perspective schematic drawing of a first embodiment of a fireplace assembly incorporating the principles of this invention, illustrating a universal fireplace box and an external peripheral framing structure;

FIG. 3 is a schematic cross-sectional drawing, in side elevation of the fireplace assembly of FIG. 2 , generally taken along the Line 3 — 3 in FIG. 2 , incorporating a self purging horizontal direct vent exhaust feature;

FIG. 4 is a schematic fractional top view drawing of the fireplace assembly of FIG. 3 ;

FIG. 5 is a perspective view of the firebox portion of the fireplace assembly of FIG. 2 ;

FIG. 6 is an enlarged fractional view of a corner portion of the firebox of FIG. 5 , illustrating the manner in which the front edge bracket thereof is embedded within the firebox wall;

FIG. 7 is a schematic drawing illustrating the fireplace assembly of FIG. 3 , mounted in a rough opening of a structure and illustrating an overlying protective roof canopy mounted to the assembly;

FIG. 8 is a schematic cross-sectional side elevation drawing of a second embodiment of a fireplace assembly incorporating the present invention and incorporating a self-purging universal horizontal/vertical exhaust vent;

FIG. 9 is a schematic top elevation drawing of the fireplace assembly of FIG. 8 .

FIG. 10 is an enlarged partial section taken through a vertical side of the U-shaped collar flange shown in FIGS. 5 and 6 disposed on a vacuum mold;

FIG. 11 is an enlarged partial section taken through a vertical side of a modified C-shaped frame disposed on a vacuum mold before removal;

FIG. 12 is a schematic enlarged partial section in elevation taken through a top wall of a fireplace box showing a two-flange collar;

FIG. 13 is an enlarged partial section in elevation taken through a top wall of a fireplace box showing a three-flange collar;

FIG. 14 is an enlarged partial section taken through a horizontal or vertical wall of a fireplace box showing a two-flange collar;

FIG. 15 is an enlarged partial section in elevation taken through a horizontal or vertical wall of a fireplace box showing a three-flange collar;

FIG. 16 is an enlarged partial section in elevation taken through a horizontal or vertical wall of a fireplace box showing a four-flange collar; and

FIG. 17 is an enlarged partial section in elevation taken through a horizontal or vertical wall of a fireplace box showing a four-flange collar.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention can be better understood by first referring to conventional prior art techniques for installing a fireplace assembly into an enclosure. FIG. 1 illustrates a schematic drawing and side elevation of a convertible dual direct-vented fireplace of the type shown and described in U.S. Pat. No. 5,647,340, incorporated by reference. The fireplace 10 is illustrated as having a vertical venting means 11 and horizontal venting means 12 . For purposes of this description, the term venting means 11 or 12 refers to the fresh air vent 13 and to the exhaust stack 14 which form the vertical venting means 1 1 , or to the similarly functioning elements 15 and 16 of the horizontal venting means 12 . The fireplace 10 is of a type prefabricated from sheet metal and is further provided with a fabricated cap 17 for sealing one of the two venting means 11 and 12 . As illustrated in FIG. 1 , the vent 11 is sealed by the cap 17 , in a manner well-known in the art.

In the FIG. 1 fireplace assembly, the combustion chamber is indicated at 20 and is generally defined by a lower panel 21 , and upper panel 22 , a rear panel 23 , and oppositely disposed side panels 24 . The lower floor of the combustion chamber is illustrated at 25 . The outer surround of the fireplace assembly is defined by an upper panel 26 , a rear panel 27 , a lower panel 28 , and oppositely disposed side panels (not illustrated) which collectively surround the combustion chamber and form a protective outer surround layer or shroud for the fireplace assembly. An intermediate back wall 30 is interposed between the rear panel 23 of the combustion chamber and the back panel 27 , and an upper intermediate wall 31 is interposed between the upper panel 22 of the combustion chamber and the upper surround panel 26 . Fresh air vents 13 and 15 connect to the passageways formed between upper walls 22 and 31 and between rear walls 23 and 30 , forming a fresh combustion air plenum 35 that extends downward and connects to a fresh combustion air passageway 35 ′ (illustrated as extending under lower panel 21 ), and which could extend directly into the combustion chamber proper 20 . The spaces between lower walls 25 and 28 , rear walls 27 and 30 and upper walls 26 and 31 collectively form a heat exchanger passageway 36 that receives room air at a lower inlet 36 a , heats the air from the heat of the combustion chamber and directs the heated air back into the room through the upper outlet port 36 b . An optional blower system (not illustrated) can be located within the heat exchange plenum 36 to facilitate movement of air through the heat exchanger 36 and into the room environment. A flat pan burner 40 is illustrated below a log system 41 . The burner 40 is connected to a gas valve 42 by means of a flexible pipe 43 in manner well-known in the art, and as described in more detail U.S. Pat. No. 5,647.340. The front of the combustion chamber is closed by an appropriate door panel. generally indicated at 33 . The vertical vent means 11 extends through the upper panel 22 , and the horizontal vent means 12 extends through the rear panel 23 .

In the standard mounting configuration for such fireplaces as illustrated in FIG. 1 , the fireplace assembly 10 is mounted within a framed enclosure 45 having lower wall framing members 45 a , back wall framing members 45 b , upper wall framing members 45 c , and sidewall framing members (not illustrated). Such enclosures also typically have an upper header 46 horizontally extending over the upper portion of the enclosure and carried by studs 46 a of the building structure. All of the inner surfaces of the framing members are enclosed by continuous wall members, generally indicated at 47 , which typically comprise a fireproof material such as sheetrock. The outer surfaces of the framing members 45 are covered by appropriate external wall members, such as siding or the like, to the extent that such surfaces are exposed to external elements and the weather. The upper outer wall portion may be shaped in the form of a rough canopy or the like. The enclosure structure is typically fully constructed prior to insertion of the fireplace assembly 10 into the assembly. Decorative trim panels, such as indicated at 34 are typically attached to the assembly after installation to fill any gaps between the outer surround of the installed assembly and the inner periphery of the enclosure.

The typical prior art techniques for installing fireplace assemblies, either entirely or partially, within walls of a building or structure generally requires that the enclosure into which the fireplace assembly is to be installed, be framed and pre-finished prior to installation of the fireplace assembly. This practice means that the fireplace assembly is one of the latest installations to be made in the construction process. Besides the costs involved with the pre-installation framing and completion of the fireplace enclosure, the fireplace assembly if preordered, is often in the way of and vulnerable to damage by construction workers during the sheetrocking and other labor intensive operations. The present invention eliminates these issues by providing a fireplace assembly that is configured to become and to be installed as a part of the initial structure framing process. Since the fireplace assembly is installed early on in the process, it is not in the way where it may be damaged during the sheetrocking and other finishing processes.

The principles of this invention can be applied to virtually any type of pre-fabricated fireplace assembly that is to be installed either wholly or partially within a wall of a structure. For example, the inventive principles can be applied to the direct vented type of fireplace illustrated at 10 in FIG. 1 . However, the cost advantages attainable by use of the present invention are best realized by using a fireplace having a fireplace box made of highly insulative materials such as reinforced fiber ceramic material (RFC). The superior insulating properties of such materials enable fabrication of a fireplace assembly for zero clearance applications, that does not require the expense of a surrounding protective shroud of the type formed by the panels 26 , 27 and 28 of the FIG. 1 fireplace assembly.

A first embodiment of a fireplace assembly 50 incorporating the principles of this invention and utilizing a universal fireplace box 51 of RFC material is illustrated in FIGS. 2 - 4 . The fireplace box 51 is preferably an open ended ceramic fireplace box that is of molded or cast construction as described in copending patent applications U.S. Ser. Nos. 09/024,285 and 08/538,866 now U.S. Pat. Nos. 5,996,575 and 5,941,237. To the extent that a more detailed description of the configuration or construction of such ceramic materials is desired, the reader is referred to the referenced patent applications, the disclosures of which are fully herein incorporated by reference. The fireplace box 51 , which is illustrated by itself in FIG. 5 , generally has an upper wall portion 51 a , a rear wall portion 51 b , a bottom wall portion 51 c and opposed sidewall portions 51 d , integrally molded together to form a one-piece fireplace box construction. The walls of the fireplace box are generally about one and a half to two inches thick. A U-shaped collar flange 52 peripherally extends around the entire rectangular front edge of the fireplace box 51 . The collar flange construction is illustrated in more detail in FIG. 6 . The flange is preferably configured of cold rolled steel with a galvanized/aluminized coating. Referring thereto, in the preferred embodiment, the flange has a first leg member 52 a , approximately two inches long, that is embedded within the ceramic body through its distal end, and is molded into the ceramic. The first leg member is perforated to enable passage of the ceramic molding material therethrough and to enhance securement of the flange to the fireplace box during molding of the box. The plane of the first leg member 52 a is embedded into the front end of the fireplace box around its entire periphery at a spaced distance of approximately one half inch back from the inner surfaces of the fireplace box at the front edge. A central portion 52 b of the collar flange lies generally co-planar with and engages the front edge of the fireplace box around its entire periphery, and forms a decorative edge for the fireplace box. A second leg portion 52 c of the collar flange completes the U-shaped bracket and extends back from the decorative front portion 52 b along the outer surface of the fireplace box for a distance of approximately one and a half inches, and serves as a fastener base member (as hereinafter described) for securing other portions of the fireplace assembly to the fireplace box.

An inner trim frame 54 may be peripherally secured to the collar bracket 52 for supporting an operable door within the fireplace box opening. Alternatively, since the U-shaped bracket 52 forms a seal with the combustion chamber of the fireplace box due to its integral construction therewith, the glass door panel may be directly secured and sealed to the front planar portions 52 b of the U-shaped bracket or to extension thereof. Referring to FIG. 2 , a decorative surround front panel 55 is secured by screws to the outer fastener leg portions 52 c of the U-shaped collar flange, which serves as a mounting base therefore. A glass door panel 56 is schematically illustrated as mounted to the front surfaces of the decorative front panel 55 .

An outer framework of building materials, generally illustrated at 60 , is secured to the fireplace assembly. In the first embodiment illustrated in FIGS. 2 - 4 , the framework 60 includes first and second rectangular 2×4 board frame members 61 and 62 , respectively located adjacent the front and the rear of the fireplace assembly. The front frame member 61 is secured through the surround panel 55 to the U-shaped collar flange 52 . The rectangular frames are longitudinally spaced from one another in the axial direction of the fireplace box, and are secured to one another by means of a plurality of lower 2×4 board stringers 63 designed to support the fireplace assembly upon a floor or other planar surface by means of a bottom side panel 67 and a plurality of lower 2×4 board stringers 63 . The stringers 63 are appropriately laterally spaced from one another to enable tines of a forklift to be inserted therebetween for moving the fireplace assembly during shipping and handling. The lower surface of the bottom wall 51 c of the fireplace box 51 is inclined at a slight angle in the direction from front to back of the fireplace box 51 , as illustrated in FIG. 3 . The frames 61 and 62 are also interconnected by means of oppositely disposed side panels 64 a and 64 b , and by an upper panel 65 . The back of the framework assembly of the first embodiment is closed by a back panel 66 . A plurality of brackets, generally indicated at 68 are secured to the front rectangular frame portion 61 at various positions therealong for mounting the fireplace assembly 50 to a rough opening framework of the structure in which the fireplace assembly is to be installed.

The framework serves multiple purposes. It acts as a packaging or shipping container for the fireplace assembly, protecting the fireplace box and assembly in general from damage during shipment and handling, and at the construction site. The entire fireplace assembly, framework included, is mounted by means of the peripheral support brackets 68 to the building framework that defines the rough opening for the fireplace assembly, in much the same manner that a window unit or other type of fenestration product is secured to its rough opening. As mounted to the rough opening, the framework 60 , which is connected to the fireplace box 51 , supports the fireplace box in its mounted position within the rough opening in the wall. Referring to FIG. 3 , it will be noted that the upper decorative panel 55 is spaced from the front surfaces of the support frame 61 by a distance which allows a panel of sheetrock to be inserted therebetween. The sheetrock is secured directly to the framing member 61 , which becomes a framing member portion of the wall of the structure in which the fireplace assembly is installed. Similarly, the back panel 66 and the side panels 64 of the framework form a portion of the external structure of the wall, to which external siding or the like can be directly applied. It will be appreciated that the tolerances between the outer surfaces of the fireplace box 51 and the inner surfaces of the surrounding framework 60 are appropriately spaced from one another to provide a safety margin for preventing overheating of the surrounding framework assembly. The particular spacing between the fireplace box and surrounding framework will be dictated by the use to which the fireplace assembly is put (i.e. whether it is a relatively low btu unit used for decorative purposes, or a relatively high btu unit used for heating purposes). Since the framework assembly is designed and applied to the fireplace assembly at the factory, where such tolerances and safety factors can be accurately controlled, jobsite contractor error in this regard is eliminated.

Referring to the schematic drawing and side elevation of FIG. 3 , the fireplace assembly illustrated is one of a type referred to as a self purging direct vent fireplace having the open-ended firebox 51 which is shown having a large opening in its upper wall 51 a for receiving an exhaust collar 70 therethrough which connects to an exhaust pipe 71 . The exhaust collar 70 is sealably connected to the upper wall 51 a of the fireplace box 51 by a U-shaped collar flange 73 that is integrally embedded within the ceramic material of the upper wall 51 a at the time of molding of the fireplace box, and is of generally the same construction of the U-shaped collar flange 52 , previously described. A second exhaust flange 75 supports the exhaust pipe 71 for safe exit through an opening in the rear wall 66 of the framework 60 . Near the bottom portion of sidewall 51 d , there is another aperture, generally designated by the letter “A” at 74 which is used for supplying combustion air to the burner system of the fireplace assembly. It will be appreciated that the fresh air aperture “A” could be located in either the side or back walls of the fireplace box.

A burner system, schematically illustrated at 76 can be of any type well-known in the art, and is preferably one which includes a gas valve 77 mounted on an appropriate pan or panel (not illustrated) and connected to a flat pan or other type of burner, generally indicated at 78 by means of a tubing assembly 79 . The burner is preferably of a type having a ceramic top that is formed as a bed of coals or bum wood and is shown in detail and described in U.S. Pat. No. 5,601,073 which issued on Feb. 11, 1997. As illustrated in FIG. 3 , a hollow log burner 80 is also connected to the flat pan burner. The log system and burner 80 are preferably supported on a removable floor panel, generally indicated at 81 which has cutouts and apertures for fitting over the flat pan burner 78 , while offering support for the log system 82 . It will be appreciated that the entire burner and floor assembly can be readily removed from the fireplace box 51 for shipping purposes and can be readily installed within the fireplace box and connected to an appropriate supply of gas at the time of installation of the system.

Referring to FIG. 7 , the fireplace assembly of FIG. 3 is illustrated as it would be mounted within a rough opening of a structure. The lower stringers 63 of the framework structure of the fireplace assembly lie upon and are supported by a lower stud member 85 defining the lower extremity of the rough opening. The fireplace assembly is then leveled within the rough opening and secured in its leveled position to the side and top frame members of the rough opening by means of the plurality of mounting brackets or flanges 68 . An upper header portion of the rough opening is generally indicated at 86 . A canopy roof, generally indicated at 83 is illustrated as having been connected between the upper stud members of the wall and the back portion of the framework of the fireplace assembly. External siding or the like can be directly applied to the rear wall 66 and to the sidewalls 64 of the framework structure. Similarly, a layer of sheetrock, generally indicated at 84 is illustrated as being secured to both the upper header framing 86 and to the front frame member 61 of the fireplace assembly. The phantom lines at 71 a indicate that the exhaust pipe could also have been directed upwardly through the upper wall of the fireplace assembly, rather than through the backwall.

It will be appreciated that many different types of surrounding framework structures can be configured within the spirit and intent of this invention. An example of an “open” framework structure, simply configured from 2×4 boards with no external sheathing or panels, is illustrated in FIGS. 8 and 9 . Referring thereto, the same internal fireplace box and burner assemblies previously described with respect to FIGS. 2 - 6 are illustrated, wherein the numerical designations of like numbered parts have been followed by a prime designation. The “open” framework configuration 60 prime of a type that may, for example, be used wherein the fireplace assembly is being inserted into an internal wall of a structure, where there is no need for a rear or side support structure for external siding or the like, or for situations wherein a customized enclosure is going to be built for the fireplace assembly. The framework 60 ′ simply includes an upper 2×4 material frame portion 90 connected to a rear rectangular frame 91 by means of several upper connecting frame members 92 a and 92 b , and by several lower interconnecting frame members 93 . While the framework 60 ′ is of open construction, its framing members are still spaced along the perimeter of and slightly beyond the outer surfaces of the fireplace box, to protect the box from injury during shipping and handling thereof. The fireplace assembly of FIGS. 8 and 9 is illustrated with a convertible exhaust outlet 95 for optional exhaust venting in either a horizontal or vertical manner.

Refer now to FIG. 10 showing a partial section in plan view taken through a vertical side of the rectangular frame 52 as it is positioned on a vacuum mold 101 , 102 when the fireplace box 51 is formed thereon encapsulating the metal surround trim or frame 52 . The frame 52 is shown having an attachment flange 52 a , a facing or front flange 52 b and a mounting flange 52 c . The frame 52 is described as a collar, a C-shaped structure and a U-shaped structure. The frame 52 is placed on the mold 102 juxtaposed mold 101 . A vacuum is applied to the left side of mold 101 causing a slurry of RCF material to build up on the right or forming side of mold 101 . The build up of wet slurry 51 is not capable of supporting itself off the mold 101 , 102 . Accordingly, the mold, frame 52 , and fireplace box 51 are removed from the forming tank (not shown) and dried as a unit until the fireplace box becomes semi-rigid. The frame 52 , when removed as part of box 51 , causes the open ends of the box 51 to remain rigid dimensionally and stable even though the box 52 is not yet dry. The box 52 may now be dried and/or fired to drive off almost all water and have a rigid fireplace box 51 .

Refer now to FIG. 11 showing a modified frame 52 f , again comprising flanges 52 a , 52 b and 52 c . Flange 52 c is shown encapsulated in slurry 51 s and the excess slurry is removed during the process of molding and drying to expose the outer surface of flange 52 c as is shown in FIG. 10 . The modified flange 52 c of frame 52 f provides a mounting surface for a metal shroud or shield all around firebox 51 when underwriter lab requirements require it, usually when mounted against an organic wooden framing.

Refer now to FIG. 12 showing an enlarged partial section in elevation taken through an L-shaped collar 120 having a horizontal attachment flange 120 a and a vertical mounting flange 120 c . A stack or outlet adapter 121 is shown schematically mounted inside of flange 120 c . Even when the adapter 121 is tightly fitted in cylindrical flange 120 c the compressible insulation of fireplace box 51 is not damaged.

Refer now to FIG. 13 showing an enlarged partial section in elevation taken through a “U” or C-shaped cylindrical collar 130 having a second mounting flange 130 d which provides additional support and protection when adapter 121 is inserted or removed.

Refer now to FIG. 14 showing an enlarged partial section in elevation taken through an L-shaped collar 140 . The adapter 121 is shown inserted from a side opposite to that shown in FIG. 12 and the numerals from FIG. 12 are used since the functions are identical, however, note that flange 120 c of collar 140 is flush with the inner surface of the opening 142 .

Refer now to FIG. 15 showing an enlarged partial section in elevation taken through a C-shaped cylindrical collar 150 . The mounting flange 130 c is flush mounted in opening 152 ; otherwise, the numerals and functions are the same as those shown in FIG. 13 .

Refer now to FIG. 16 showing an enlarged partial section in elevation taken through a collar 160 having four flanges. In this embodiment, the mounting flange 160 c extends through opening 162 and is provided with a second mounting flange 160 d . The attached flange 160 a comprises a vertical leg portion. This modified collar 160 is designed to support a vertical upward force applied at adapter 121 .

Refer now to FIG. 17 showing a collar 170 identical to collar 160 and is designed to support a vertical downward force applied at adapter 121 . The numerals used in FIG. 17 which are the same as those used in FIG. 16 do not require additional explanation.

Having explained six integrally molded cylindrical shaped collars, it will be understood that other shapes of collars may be employed should the need arise. The collars shown may be integrally molded into any of the fire walls of the fireplace box 51 to provide means for attaching pipes or stacks or to reinforce openings that are not subject to breaking of the light non-porous-to-gas RCF fireplace box 51 .

Thus, those skilled in the art will appreciate that a fireplace assembly of unique construction and use has been disclosed. Those skilled in the art will appreciate that other variations of the invention from those specific preferred embodiments described can be configured within the broad spirit and scope of this invention. For example, while the preferred embodiments of the invention that have been described were described with reference to use of an external framing structure in association with a highly insulative ceramic fireplace box, the invention would also apply to prefabricated fireplace boxes of sheet metal construction such as illustrated by the direct vented fireplace assembly of FIG. 1 . In such instances, additional insulation would most likely be required to be placed between the outer surrounding shroud of the fireplace assembly and the framing components to insulate the framing components from heat transmitted from the metal components of the fireplace box.

The above specification, and examples have been provided to illustrate specific examples of embodiments incorporating the principles of the invention. Those skilled in the art will readily recognize other applications and configurations that fall within the scope of this invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.

Claims

1. A prefabricated fireplace box comprising:(a) a monolithic open-ended fireplace box; (b) said fireplace box having at least five interconnected walls of homogeneous refractory ceramic fiber material molded in or on a rigid mold and dried sufficiently to form a semi-rigid fireplace box; (c) said semi-rigid fireplace box defining a combustion chamber inside of said five interconnected walls; (d) a rigid metal frame comprising flat vertical facing flanges outside of said semi-rigid fireplace box, and (e) said rigid metal frame having attachment flanges extending normally from said facing flanges and integrally molded into the open end of said combustion chamber walls for rendering the front end of said semi-rigid fireplace box rigid and removable from said mold.

2. A prefabricated fireplace box as set forth in claim 1 wherein said rigid rectangular metal frame comprises a precision rigid rectangular frame surrounding the front face of said fireplace box.

3. A prefabricated fireplace box as set forth in claim 2 wherein said rigid rectangular frame comprises a channel or C-shape in section.

4. A prefabricated fireplace box as set forth in claim 3 wherein the outer flange of said C-shape is molded into the outer surface of said molded fireplace box.

5. A prefabricated fireplace box as set forth in claim 2 which further includes an exhaust outlet collar having at least one attachment flange integrally molded into said fireplace box.

6. A prefabricated fireplace box as set forth in claim 5 wherein said exhaust outlet collar comprises a non-symmetrical C-shape having one flange molded into said fireplace box.

7. A prefabricated fireplace box as set forth in claim 5 wherein said exhaust outlet collar is L-shaped in section.

8. A prefabricated fireplace box as set forth in claim 5 wherein said exhaust outlet collar is shaped in the form of two L-shapes having four flanges.

9. A method of making an accurately dimensional open-ended fireplace box for a fireplace, comprising the steps of:making a wet moldable slurry of refractory ceramic fibers (RCF) and an aqueous non-organic binder, placing a rigid prefabricated fireplace metal frame having a facing flange and an attachment flange in or on a rigid forming mold, supporting the front face of said metal frame in or on said mold, forming said wet moldable slurry onto said rigid mold and around said attachment flange on said rigid frame to provide a wet fireplace box on said mold, and drying and integrally molding the fireplace box on said rigid mold to provide a semi-rigid open end on said open-ended fireplace box that is removable from said rigid mold without distortion.

10. A method as set forth in claim 9 which further includes removing said open-ended fireplace box from said mold while said fireplace box is semi-rigid.

11. A method as set forth in claim 10 which further includes drying said open-ended fireplace box to provide a monolithic RCF fireplace box with five interconnected walls defining a combustion chamber inside of said five walls.

12. A method as set forth in claim 9 where said step of forming comprises molding said slurry completely around an attachment flange on said frame.

13. A method as set forth in claim 9 wherein said frame trim comprises a C-shape having three flanges and molding at least two of said flanges into said fireplace box.

14. A method as set forth in claim 9 wherein the step of forming includes the step of forming said slurry around an attatchment flange of an exhaust collar.

15. A method as set forth in claim 14 wherein said exhaust collar comprises an L-shape and the flange of said L-shape with an annular flange is integrally molded into said fireplace box.

16. A prefabricated fireplace box comprising:(a) a monolithic open-ended fireplace box; (b) said fireplace box having at least five interconnected walls of homogeneous refractory ceramic fiber material molded in or on a rigid mold and dried sufficiently to form a semi-rigid fireplace box; (c) said semi-rigid fireplace box defining a combustion chamber inside of said five interconnected walls; (d) a rigid channel or C-shape rectangular frame comprising a vertical facing flange outside of said semi-rigid fireplace box, and (e) a horizontal attachment flange integrally molded into the open end of said combustion chamber walls for rendering the front end of said semi-rigid fire-place box rigid and removable from said mold fireplace box.