Patent Application
20100239990
Gas burners are used in gas fireplace units for producing flames for visual effect and/or heating purposes. Typically, gas burners are used to combust a gas/air mixture thereby producing flames. Often times, gas burners are designed to produce flames that mimic an appearance of a natural, wood burning fire. More common gas burners include tube burners and pan burners. Although the tube- and pan-designs are common, other designs have become more common—including gas burners shaped to mimic an appearance of wood log, for example.
Some of the inventive aspects described herein relate to a gas burner having a high degree of versatility in flame presentation, including, for example, the ability to hide various portions of the burner, produce various flame effects, and provide a slimmer, vertically-oriented burner. The versatility of various embodiments described herein allows greater freedom in fireplace design and flame presentation.
In some embodiments, a gas burner assembly includes a first sheet, a second sheet, and a conduit. The first sheet has an inner face, an outer face, an upper portion, and a lower portion. The second sheet also has an inner face, an outer face, an upper portion and a lower portion. The first and second sheets are secured in a substantially vertical orientation and relative to one another such that the first and second sheets are separated by a gap that defines a substantially vertical manifold between the inner faces of the first and second sheets. The gap also defines a substantially vertical manifold between the inner faces of the first and second sheets and an elongate opening between the upper portions of the first and second sheets, the opening forming an outlet from the substantially vertical manifold. The conduit is in communication with the manifold, the conduit being adapted for connection to a source of gas.
While multiple embodiments are disclosed, still other embodiments of the present invention will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.
While the invention is amenable to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and are described in detail below. The intention, however, is not to limit the invention to the particular embodiments described. On the contrary, the invention is intended to cover all modifications, equivalents, and alternatives failing within the scope of the invention as defined by the appended claims.
Some of the inventive aspects described herein relate to a gas burner having a high degree of versatility in flame presentation in a heating unit such as a fireplace, including, for example, the ability to hide various portions of the burner assembly, produce various flame effects, and/or provide a slimmer, vertically-oriented burner assembly. The versatility of various embodiments described herein helps provide greater freedom in fireplace design and flame presentation. Although embodiments having the above-described features are provided herewith, additional or alternative features and associated advantages are also made apparent.
The outer housing 12 is formed of any of a variety of suitable materials, including sheet metals, for example. Likewise, the combustion chamber 14 is formed of any of a variety of suitable materials, including molded ceramic fiber and binder composites, for example. The combustion chamber 14 defines a combustion enclosure 20 adapted to receive heat and combustion products from flames 22 produced by the burner assembly 18. The combustion chamber 14 includes a transparent front portion 24 (e.g., one or more sheets of transparent glass) for viewing into the combustion enclosure 20, as well as a transparent rear portion (not shown) as desired. In some embodiments, the combustion chamber 14 includes additional transparent portions (e.g., side, back, etc.) for viewing into the combustion enclosure 20.
The gas source 16 is optionally a regulator connected to an external gas line (not shown), such as a natural gas or LP gas line associated with residential, commercial, or other structure. Other gases are also contemplated, such as hydrogen, for example. In general terms, the burner assembly 18 of the fireplace 10 is adapted to direct flames into the combustion enclosure 20 of the combustion chamber 14.
Additional or alternative fireplace components associated materials, and configurations suitable for use in association with the burner assembly 18 are provided in various products offered by Hearth and Home Technologies, Inc. of Minnesota. As examples of patent literature, U.S. Pat. No. 5,016,609, entitled “Direct Vented Multi Glass Side Fireplace,” U.S. Pat. No. 5,647,340, entitled “Convertible Dual Direct-Vented Fireplace,” U.S. Pat. No. 5,947,112, entitled “Prefabricated Fireplace Exhaust Plenum Structure,” U.S. Pat. No. 6,170,481, entitled “Open Ended Molded Fireplace Box and Method,” and U.S. Pat. No. 7,077,122, entitled “Reduced Clearance Gas Fireplace,” the entire contents of all of which are incorporated herein by reference, provide descriptions of additional or alternative fireplace components associated materials, and configurations suitable for use with the burner assembly 18, according to some embodiments.
As shown in
In some embodiments, various components of the burner assembly 18 are sandwiched together to form a thin, generally vertical structure with the fasteners 70 securing the structure together. Generally, the first and second frame members 30, 32 (as well as the seals 38, 46, 58 and spacers 40, 48) form an outer housing around the first and second plates 52, 54. As described in greater detail, the burner assembly 18 has an upper manifold 72 (
In some embodiments, the first frame member 30 includes a pair of feet 100 at the lower portion 96, of the first frame member 30 adapted for maintaining the burner assembly 18 (
Though a variety of materials and forming processes are contemplated, the first upright 80, the second upright 82, and the lateral member 84 are optionally formed from a single piece of sheet metal or other material using bending and/or stamping processes, for example. The first upright 80, the second upright 82, and the lateral member 84 combine to form a substantially U-shaped frame, where the central viewing area 88 is defined on three sides by the first upright 80, the second upright 82, and the lateral member 84 and is open at the upper portion 94.
The second frame member 32 also defines an outer face 120, an inner face 122 (
The various seals are shown and described below as pre-formed pieces (e.g., being molded, stamped, or cut out) of material. In some embodiments, however, one or more of the seals are deposited or applied as liquids or gels that cure or are otherwise formed.
The lower body 144 has an opening 148 which, as described in greater detail below, helps provide means for forming a gas plenum. As shown, the opening 148 is substantially rectangular in shape and about 34.5 inches wide and from about 1 to about 3 inches tall (e.g., about 2 inches tall), although a variety of shapes and dimensions are contemplated. The lower body 144 has an upper piece 149 above the opening 148 and a lower piece 150 below the opening 148. The open interior 146 is sized to be substantially smaller than the first plate 52 such that the first arm 140, the second arm 142, and the upper piece 149 are sized to overlap the first plate 52 as described in greater detail below.
The second intermediate seal 46 is substantially similar to the first intermediate seal 38, according to some embodiments. As such, where features of the second intermediate seal 46 are described and shown they are designated by a similar reference number to the first intermediate seal 38 followed by a “B.”
The first spacer 40 includes a first arm 152, or first side portion, a second arm 154, or second side portion, and a lower body 156 connecting the first and second arms 152, 154. The first spacer 40 also has an upper portion 155. In some embodiments, the first spacer 40 is substantially U-shaped, defining an open interior 158 bounded by the first arm 152, the second arm 154, and the lower body 156. The open interior 158 is sized to be substantially complementary in size to the first plate 52, such that the first plate 52 is able to be received in the open interior 158 in a substantially complementary fit. The first spacer 40 also includes a plurality of fastener holes 159 disposed about the first spacer 40.
The lower body 156 has an opening 160 which, as subsequently described, helps provide means for forming a lower manifold, or plenum of the burner assembly 18. As shown, the opening 160 is substantially rectangular in shape and about 34.5 inches wide and about 2 inches high, although a variety of shapes and dimensions are contemplated (e.g., from about 1 inch to about 3 inches in height). The lower body 156 defines an upper piece 162 above the opening 160 and a lower piece 164 below the opening 160.
The second spacer 48 is substantially similar to the first spacer 40, according to some embodiments. As such, where features of the second spacer 48 are described and shown they are designated by a similar reference number to the first spacer 40 followed by a “B.”
As shown in
In some embodiments, the inner and/or outer faces 180, 182 of the first plate 52 are substantially planar, where the inner and/or outer faces 180, 182 are optionally smooth (e.g., as with typical sheet glass) or include surface features (e.g., bumps, ridges, dimpling, facets, or other features) while being considered substantially planar. In some other embodiments, the inner and/or outer faces 180, 182 are not substantially planar (e.g., including larger-scale waves or bends). For example, the first and second plates 52, 54 are optionally substantially S-shaped and fit together, at a spaced relationship, in a complementary manner.
The second plate 54 is optionally substantially similar to the first plate 52, according to some embodiments. As such, where features of the second plate 54 are described and shown they are designated by a similar reference number to the first plate 52 followed by a “B.” Each of the first and second plates are optionally described as panels, planer members, or sheets as desired.
The inner seal 58 is substantially U-shaped, defining an open interior 210 bounded by the first arm 202, the second arm 204, and the lower body 206. The open interior 210 is sized to be less wide than the first and second plates 52, 54 such that the first and second arms 202, 204 are sized to abut the first and second plates 52, 54 upon assembly of the burner assembly 18. In turn, the open interior 202 is substantially taller in height than the first plate 52 to leave space under the first and second plates 52, 54. In particular, the first and second arms 202, 204 are adapted to overlap the first plate 52 while the lower body 206 resides below the first and second plates 52, 54 at an offset from the bottom edges 186, 186B of the first and second plates 52, 54. In some embodiments, the lower body 206 is about 0.6 inches in height, for example.
As shown in
As shown in
In some embodiments, assembly includes disposing the first and second plates 52, 54 in a substantially parallel, spaced relationship with the inner seal 58 disposed between the first and second plates 52, 54. The inner seal 58 is optionally substantially compliant and helps reduce the effects of irregularities, misalignment, and/or stress concentrations on the plates 52, 54. Where the plates 52, 54 are formed of glass or other ceramic material, such compliance is useful to prevent cracking of the plates 52, 54, although the first and second spacers 40, 48 also optionally assist in this regard.
In some embodiments, the inner seal 58 is abutted against the inner face 182 of the first plate 52 and inner face 182B of the second plate 54, respectively such that the inner seal 58 runs along the first and second side edges 188, 190 of the first plate 52 and first and second side edges 188B, 190B of the second plate 54. The upper portion 200 of the inner seal 58, the top edge 184 of the first plate 52, and top edge 184B of the second plate 54 are substantially aligned with one another and the lower body 206 of the inner seal 58 is positioned below the bottom edge 186 of the first plate and bottom edge 186B of the second plate 54 to define an opening 240 forming part of the lower manifold 74 and being in communication with the upper manifold 72 as shown in
In some embodiments, the first spacer 40 receives the first plate 52 in the open interior 158 (
In some embodiments, the first intermediate seal 38 is abutted against the outer face 180 of the first plate 52, as well as the first spacer 40, and the second intermediate seal 46 is abutted against the outer face 180B of the second plate 54, as well as the second spacer 48. In particular, the intermediate seals 38, 46 are abutted against the first and second plates 52, 54, respectively, toward the outer perimeters of each of the first and second plates 52, 54. The upper portion 145 of the first intermediate seal 38 and the upper portion 145B of the second intermediate seal 46 are generally aligned with the top edges 184, 184B of the first and second plates 52, 54, respectively. In turn, the openings 148, 148B of the first and second intermediate seals 38, 46 are generally aligned with each other and are positioned below the bottom edges 186, 186B of the first and second plates 52, 54.
As shown in
In some embodiments, the outer, side edges 188, 188B and 190, 190B are sealed such that a substantially thin, vertical chamber—the upper manifold 72—is formed between the first and second plates 52, 54; a thin, elongate inlet into the upper manifold 72 is formed, or otherwise defined, along the bottom edges 186, 186B of the first and second plates 52, 54; and an elongate outlet from the upper manifold 72 formed, or otherwise defined, along the top edges 184, 184B. In particular, a substantial perimeter portion of the first and second plates 52, 54 is sealed together to form the upper manifold 72 with the gap 242 defined between the first and second plates 52, 54.
In some embodiments, the gap 242 is substantially elongate and continuous at the top edges 184, 184B of the first and second plates 52, 54 to help define an elongate outlet from the burner assembly 18. The gap 242 is optionally substantially continuous between the first and second plates 52, 54 (from top-to-bottom and from side-to-side), although non-uniform spacing between the first and plates 52, 54 is also contemplated (e.g., a top profile of the gap 242 at the top edges 184, 184B is substantially thin and rectangular according to some embodiments, although sinusoidal, jagged, or other profiles are contemplated to modify flame shape and/or other flame and visual characteristics). In some embodiments, the gap 242 extends without interruption for a length of about 33.5 inches at the top edges 184, 184B at a thickness of about 0.06 inches, for example, although a variety of dimensions are contemplated. In some embodiments, the gap 242 is less than about 0.5 inches thick. In some other embodiments, a gap thickness from about 0.03 inches to about 0.125 inches is contemplated. A variety of lengths are also contemplated, including the gap 242 extending continuously without interruption from about 3 inches to about 48 inches, for greater than about 3 inches, greater than about 12 inches, or greater than about 24 inches, for example.
In some embodiments, the upper manifold 72 is from about 3 inches wide to about 48 inches wide, is from about 3 inches in height to about 36 inches in height, and is from about 0.03 inches in thickness, or depth, to about 0.125 inches in thickness, for example. In turn, the lower manifold 74 is from about 1 inches in height to about 3 inches in height; is from about 0.25 inches in thickness to about 2 inches in thickness; and is from about 3 inches wide to about 48 inches wide, for example, although a variety of dimensions are contemplated.
As shown in
The connector 62 is secured to the opening 102 of the first frame member 30. In particular, the flange 212 (
As shown in
The connector 62 is placed in communication with the gas source 16, including any flow regulators, means for varying air-to-gas mixture ratios, or other equipment feeding the burner assembly 18 through the connector 62.
Where the first and second plates 52, 54 (
In some embodiments, this lends an appearance that a source of the flames 22 is substantially hidden. This hidden-source feature is useful in various scenarios, including creating a more realistic look with a log set or an eye-catching visual effect like that generally shown in
In some embodiments, the burner assembly 18 is used in a method of producing the flames 22 to produce a substantially continuous, uninterrupted body of flames 22 extending across the gap 242 at the top edges 184, 184B. In contrast to burners with a multitude of distinct holes for delivering combustible gases, the burner assembly 18 optionally provides a single, substantially thin and elongate aperture—the gap 242. In at least such manner, the gap 242 is optionally selected to provide means for forming a substantially continuous body of flames 22 across the upper portion of the burner assembly 18. It should also be understood that a spacing, length, and shape (e.g., top profile) of the gap 242 is selected to provide various BTUs from the burner assembly 18 as desired.
In some embodiments, the burner assembly 18 is used to create an effect whereby the flames 22 race from the first side 26 of the burner assembly 18 to the second side 28 of the burner assembly 18. In particular, by locating the igniter 66 at the first side 26 of the burner assembly 18 the flames 22 start at the first side 26 and travel to the second side 28. In still other embodiments, an additional igniter 66 is placed at the second side 28 of the burner assembly 18 to provide further versatility in a direction the flames 22 travel across the gap 242 (e.g., left-to-right, right-to-left, and/or meeting-in-the-middle effects).
As shown, the fireplace 310 has a substantially thin profile, although wider, more traditional fireplace designs are contemplated. In some embodiments the fireplace 310 includes features for creating reflective visual effects. For example, one or both of the front and rear panels 320, 322 are optionally formed of a reflective material, such as a one-way reflective material (e.g., Mirropane(™) materials available from Toledo—Pilkington North America Inc. of Toledo, Ohio).
In some embodiments, the front panel 320 includes an outer surface 320A and in inner surface 320B, the front panel 320 being reflective at the inner surface 320B and allowing viewing into the fireplace 310 through the outer surface 320B. In some embodiments, the rear panel 322 includes an outer surface 320A and an inner surface 320B having substantially similar properties, where the outer surface 322A allows viewing into the fireplace 310 and the inner surface 322B provides reflective properties. As shown, the inner surfaces 320B, 322B of the front and rear panels 320, 322 are oriented inwardly, toward one another and the outer surfaces 320A, 322B face away from one another.
In some embodiments, light from fireplace flames generated by the burner 18 (not shown) is reflected back and force by the reflective inner surfaces 320B, 322B as represented by the arrow 330 to create a reflective visual effect, such as an “infinity effect.” In particular, in some embodiments, the fireplace 310 is adapted to create an illusion of depth using the infinity effect, where to a viewer it appears there are a series of layers of flames emanating from within the fireplace 310 due to the repeated reflection of the flames by the inner surfaces 320B, 322B. Thus, one method of presenting fireplace flames to a user for viewing includes optically reflecting flames to create the illusion of a plurality of flames within the fireplace 310 that are not otherwise actually present. In some embodiments, the optical effect shifts and moves depending on the viewer's viewing angle. Additionally, the inner surfaces 320B, 322B are optionally substantially parallel with one another, or can be angularly offset to vary a generated optical, or visual effect as desired.
Viewing panels having reflective properties can be utilized to achieve a variety of other, additional or alternative effects. For example, in some other embodiments, one or both of reflective surfaces 320B, 322B are oriented outwardly, toward a user, and the front and/or rear panels 320, 322 are adapted such that when turned off, a viewer sees an external, reflective surface substantially similar to a mirror, for example. When turned on, however, the front and/or rear panels 320, 322 become substantially see-through due to the internal light generated by the flames, allowing viewing of the flames generated in the fireplace 310. Thus, in one method of using the fireplace 310, the interior of the fireplace 310 is substantially obscured from view as desired (e.g., when not in operation) and, for example, even though a room in which the fireplace 310 is installed is illuminated.
In some embodiments, the vent assembly 318 is particularly useful for installation in a relatively thin wall 344. Generally, the wall 344 is formed by a plurality of structure members 346 (e.g., wall studs) and appropriate facing members 348 (e.g., dry wall). The outer and inner duct members 338, 340 are substantially rectangular in shape, helping to allow the outer profile of the vent assembly 318 to be reduced while retaining sufficient air flow space (e.g., relative to traditional, round vent assembly designs). In particular, the outer and inner duct members 338, 340 each define a substantially thin rectangular profiles and are secured relative to one another to form an air gap between them. In some embodiments, the air gap between the outer and inner duct members 338, 340 acts as a plenum for supplying fresh air into the fireplace 310 and the inner duct 340 provides a plenum for taking exhaust air out of the fireplace 310, the vent assembly 318 being in communication with a combustion chamber of the fireplace 310 and air supply plenum(s) of the fireplace 310.
In some embodiments, the vent assembly 318 is adapted to be installed in wall 344 having an open interior about 5.5 inches wide, for example, such as that formed using a standard 2 inch×6 inch wall stud configuration. In particular, the dimensions of the outer duct 338 and inner duct 340 are selected to allow sufficient spacing between structure members 346 and facing members 348 of the wall 344 to prevent overheating or address other building and safety concerns, while providing sufficient air flow into and out of the fireplace 310.
In view of the foregoing, in some embodiments the fireplace 10 is optionally substantially thin, overall, and installed in a standard wall 344 (e.g., a 2×6 stud wall) with the narrow vent assembly 318 being hidden within the wall 344. If desired, the fireplace 10 includes the middle portion 300 of the fireplace being substantially transparent from-front to-back, as well as the first and second plates 52, 54 being substantially transparent, such that the fireplace 10 provides a viewing window through the wall 344 that is at least largely unobscured by the burner assembly 18 as shown in
Although some examples of flame effects and fireplace installations and configurations have been described, it should be understood a variety of different effects, configurations, and combinations thereof are contemplated. Additionally, although the burner assembly 18 is shown and described with substantially rectangular first and second plates 52, 54, in other embodiments the plates 52, 54 take a variety of shapes. For example, another burner assembly 418 is shown in
Various modifications and additions can be made to the exemplary embodiments discussed without departing from the scope of the present invention. For example, while the embodiments described above refer to particular features, the scope of this invention also includes embodiments having different combinations of features and embodiments that do not include all of the described features. Accordingly, the scope of the present invention is intended to embrace all such alternatives, modifications, and variations as fall within the scope of the claims, together with all equivalents thereof.
