Abstract:
A simulated electric glowing embers system disposed within a fireplace is provided. One embodiment discloses, a fireplace comprising an enclosure defining a chamber, a support structure disposed within the chamber, a plurality of translucent artificial embers disposed upon a top surface of the support structure, and a light source positioned to pass light through at least a portion of the support structure to illuminate the translucent artificial embers. Another embodiment discloses, an apparatus for electrically simulating glowing embers within a fireplace comprising an ember support bed, a plurality of translucent artificial embers individually arrangeable upon a top surface of the ember support bed, and a light source positioned to pass light through at least a portion of the ember support bed to illuminate the loose translucent artificial embers. A method for electrically simulating glowing embers within a fireplace is also provided.

Description:
FIELD OF THE INVENTION  
         [0001]    This invention relates to fireplaces. In addition, the invention relates to a simulated electric glowing embers system disposed within a fireplace.  
         BACKGROUND OF THE INVENTION  
         [0002]    Gas, electric, and wood burning fireplaces are an efficient method for providing warmth and creating the appeal of a fire within a room. Fireplaces have become commonplace in today&#39;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 on fireplaces.  
           [0003]    The representation of glowing embers in such fireplaces is desirable to provide the realistic effect of a fire. Previous systems created to provide artificial glowing embers typically call for a glass panel with artificial embers fused to the panel and a light source positioned below the panel to illuminate the embers and thereby create the illusion of glowing embers. However, such systems have several drawbacks.  
           [0004]    First, previous systems do not perform well in high temperatures. The materials used to create the artificial embers break down at the higher temperatures found in fireplaces, and such systems require that the illumination device be remotely positioned from the combustion chamber enclosure because of the intense heat created in the combustion chamber. Second, the individual simulated glowing embers provided in the systems are not movable or adaptable to different burning environments because the simulated embers in the previous systems are fused together and to the glass panel. Third, the previous systems fail to provide the most aesthetically appealing embers because the artificial embers are fused and therefore create only a two-dimensional look. Fourth, the composition of the materials selected to create the artificial embers do not create a naturally looking ember bed.  
         SUMMARY OF THE INVENTION  
         [0005]    Generally, the present invention relates to gas, electric, or wood burning fireplaces. One embodiment may include a fireplace comprising an enclosure defining a chamber, a support structure disposed within the chamber, a plurality of translucent artificial embers disposed upon a top surface of the support structure; and a light source positioned to pass light through at least a portion of the support structure to illuminate the translucent artificial embers.  
           [0006]    In another respect, the invention is directed to a fireplace comprising an enclosure including a support structure, a plurality of translucent artificial embers disposed upon a top surface of the support structure, and a light source positioned to pass light through at least a portion of the support structure to illuminate the translucent artificial embers.  
           [0007]    In another respect, the invention is directed to an apparatus for electrically simulating glowing embers within a fireplace comprising a support structure, a plurality of translucent artificial embers disposed upon a top surface of the support structure, and a light source positioned to pass light through the ember support bed to illuminate the translucent artificial embers.  
           [0008]    In another respect, the invention is directed to an apparatus for electrically simulating glowing embers within a fireplace comprising an ember support bed, a plurality of translucent artificial embers individually arrangeable upon a top surface of the ember support bed, and a light source positioned to pass light through at least a portion of the ember support bed to illuminate the loose translucent artificial embers.  
           [0009]    In another respect, the invention is directed to an apparatus for electrically simulating glowing embers within a fireplace comprising a means for supporting a plurality of translucent artificial embers and a means for illuminating the translucent artificial embers.  
           [0010]    In another respect, the invention is directed to a method for electrically simulating glowing embers within a fireplace, the method including: providing an enclosure defining a combustion chamber, disposing a support structure within the combustion chamber, arranging a plurality of translucent artificial embers on a top surface of the support structure, and passing light through at least a portion of the support structure to illuminate the translucent artificial embers.  
           [0011]    The above summary of the present invention is not intended to describe each disclosed embodiment or every implementation of the present invention. The figures and the detailed description that follow more particularly exemplify these embodiments. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]    The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:  
         [0013]    [0013]FIG. 1 is a schematic side cross-sectional view of an embodiment of a direct vent gas fireplace incorporating an embodiment of the simulated electric glowing ember system, according to the invention;  
         [0014]    [0014]FIG. 2 is a schematic detailed view of the embodiment of the simulated electric glowing ember system of FIG. 1;  
         [0015]    [0015]FIG. 3 is a schematic top view of one embodiment of the support structure of FIG. 1;  
         [0016]    [0016]FIG. 4A is a schematic top view of one embodiment of an ember support bed, according to the invention;  
         [0017]    [0017]FIG. 4B is a schematic top view of a second embodiment of an ember support bed, according to the invention;  
         [0018]    [0018]FIG. 4C is a schematic top view of a third embodiment of an ember support bed, according to the invention;  
         [0019]    [0019]FIG. 5 a schematic side cross-sectional view of a second embodiment of a direct vent gas fireplace incorporating a second embodiment of the simulated electric glowing ember system, according to the invention;  
         [0020]    [0020]FIG. 6 is a schematic detailed view of the embodiment of the simulated electric glowing ember system of FIG. 5;  
         [0021]    [0021]FIG. 7 is a schematic side cross-sectional view of a third embodiment of a direct vent gas fireplace incorporating a third embodiment of the simulated electric glowing ember system, according to the invention;  
         [0022]    [0022]FIG. 8 is a schematic side cross-sectional view of an embodiment of an electric fireplace incorporating the simulated electric glowing ember system of FIG. 2, according to the invention;  
         [0023]    [0023]FIG. 9 is a schematic side cross-sectional view of an embodiment of a multisided gas fireplace incorporating an embodiment of the simulated electric glowing ember system of FIG. 2, according to the invention; and  
         [0024]    [0024]FIG. 10 is a schematic front cross-sectional view of the multisided gas fireplace of FIG. 9 incorporating the simulated electric glowing ember system of FIG. 2. 
     
    
       [0025]    While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.  
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0026]    The present invention relates to gas, electric, or wood burning fireplaces. In particular, the present invention is directed to a simulated electric glowing embers system disposed within a fireplace. While the present invention is not so limited, an appreciation of various aspects of the invention will be gained through a discussion of the examples provided below.  
         [0027]    Referring to FIG. 1, a side elevation in section of a direct vent gas fireplace  100  is shown including a simulated glowing ember system  110 . An example of a direct vent fireplace is of the type shown and described in U.S. Pat. No. 4,793,322, herein incorporated by reference.  
         [0028]    Fireplace  100  includes an enclosure  120  that defines a chamber  122 . A portion or all of the enclosure  120  can be used for the combustion of burnable or combustible fuels. It will be understood that as used herein, the term “enclosure” is any structure that at least partially surrounds the simulated glowing ember system and is intended to be included in embodiments of all types of known fireplaces, including fireplaces that simulate combustion and do not combust a burnable or combustible fuel. An example of an enclosure that does not include combustion within its defined chamber is illustrated as enclosure  720  in an embodiment disclosed in FIG. 7, which defines chamber  722 .  
         [0029]    In one embodiment of the invention shown in FIG. 1, the glowing embers system  110  is shown disposed within the chamber  122  between a gas burner  123  and a bottom panel  125  of the enclosure  120 . The gas burner is generally located at  123 , but not specifically illustrated in FIG. 1. The glowing embers system  110  includes a support structure  124 , a plurality of translucent artificial embers  126  disposed upon the support structure  124 , and light source  128 . At least a portion of the support structure  124  allows light to pass from the light source  128  to the translucent artificial embers  126  to simulate the glowing embers of a fire within a fireplace.  
         [0030]    In FIG. 1, the glowing ember system  110  is shown, for example, disposed within a direct vent fireplace  100 . FIG. 2 shows in greater detail an embodiment illustrating the glowing embers system  110  of FIG. 1. Some examples of additional fireplace structures with which the glowing ember system of this invention could be used include universal vent, horizontal/vertical vent, B-vent, and dual direct vented fireplaces, as well as multisided units having two or three glass panels as side panels, or in any other unit used as a gas, electric, or wood burning fireplace, stove or insert.  
         [0031]    As shown in FIG. 1, the support structure  124  can divide the chamber  122  into a combustion air chamber  162  and a combustion chamber  163 . The support structure  124  and that portion of the enclosure  120  in which combustion occurs form the combustion chamber enclosure  121  and define the combustion chamber  163 . The support structure  124  can include a raised floor  130  and an ember support bed  132 . The raised floor  130  is positioned above the bottom panel  125  of the enclosure  120 .  
         [0032]    Referring to FIG. 3, a top schematic view of the ember support bed  124  disposed upon the raised floor  130  of FIG. 1 is shown. The ember support bed  132  is placed on a top surface  134  of the raised floor  130 . The raised floor  130  can include, for example, a rectangular opening over which is placed the glowing ember support bed  132 . The opening can be any other desired shape or can include multiple openings. The raised floor  130  and ember support bed  132  can optionally define one or more air gaps  137  to allow fresh combustion air to pass into the chamber  122 . The ember support bed  132  can be held into place over the light source with, for example, sheet metal clamps. Any other suitable means, such as high temperature adhesive, flanges, or screws, can alternatively be used to hold the ember support bed in position.  
         [0033]    Alternatively, the raised floor can be constructed so the top surface of the ember support bed is positioned at approximately the same level as the top surface of the raised floor. For example, the raised floor can include a recessed area sized to fit the ember support bed and include flanges to support the ember support bed above the bottom panel of the enclosure.  
         [0034]    One embodiment of the ember support bed  132  shown in FIG. 1 is a solid plate that may be constructed of material such as ceramic glass, tempered glass, or a ceramic/glass composite material. The solid plate is constructed of a clear or translucent material that allows light from the light source  128  to pass through to translucent artificial embers  126 . A typical ceramic glass plate can withstand temperatures in excess of 1400 degrees Fahrenheit. A typical tempered glass plate can withstand temperatures in excess of 600 degrees Fahrenheit. The glass can be colored with stove paint to enhance the glowing color of the translucent artificial embers. Alternatively, the glass plate can be formed into colored glass for generating a desired glowing ember effect.  
         [0035]    Other materials that can withstand high temperatures that can be present within the combustion chamber can also be used to construct the plate, such as, for example, metal. Further, a combination of two or more materials may be bonded together to form the plate.  
         [0036]    In the embodiment shown in FIG. 1, the ember support bed  132  is a non-perforated plate of material. Examples of other configurations for ember support beds are shown in FIGS.  4 A- 4 C. In a second ember support bed embodiment, illustrated in FIG. 4A, a wire mesh ember support bed  432 A can be used having individual longitudinal wires  433  and latitudinal wires  435 . The spaces  437  between wires may vary in size so long as the spaces  437  are not large enough to allow an individual translucent artificial ember to pass through the ember support bed  432 A.  
         [0037]    In a third ember support bed embodiment includes a plate  432 B defining a plurality of slots  439  (FIG. 4B). The slots  439  may be of varying dimension, so long as the space is not large enough to allow individual translucent artificial embers to fall through the ember support bed  432 B.  
         [0038]    In a fourth ember support bed embodiment shown in FIG. 4C, the ember support bed  432 C is formed with a plurality of apertures  441 . Once again, the diameter of each aperture  441  must be less than the size of individual translucent artificial embers.  
         [0039]    The ember support beds shown in FIGS. 1 and 4A- 4 C are by way of example only, and many other configurations are possible. For example, the surface of the ember support beds can include, for example, multiple elevations to aid in the placement of translucent artificial embers at different pitches and heights. Further, the ember support bed need not be a separate component, but may be formed integrally with other components of the fireplace, such as the raised floor  130  shown in FIG. 1.  
         [0040]    The ember support bed shown in the various embodiments can be constructed of various types of materials and preferably of ceramic or glass, or other suitable high-temperature materials, such as metal or refractory materials. The wire mesh, slotted, and aperture configurations of FIGS.  4 A- 4 C also allow for combustible gas, as shown, for example in FIGS. 5 and 6, or air, as shown in FIG. 7, to pass through the ember support bed.  
         [0041]    The translucent artificial embers  126  can be disposed on the ember support bed  132  in any arrangement desired. The translucent artificial embers  126  are constructed as individual pieces that allow for increased placement flexibility thereof upon the ember support bed  132 . The ember support bed  132  can be constructed of a clear or translucent material, such as high-temperature ceramic glass, to allow light to pass therethrough from the light source  128  to the translucent artificial embers  126 .  
         [0042]    The translucent artificial embers  126  are not integrally attached to each other or to the ember support structure  132 . Because the translucent artificial embers are not fused to the ember support structure, there is use flexibility in the amount of artificial embers that can be provided and the arrangement of the artificial embers on the support structure. During or after installation of the fireplace, translucent artificial embers  126  may be added, removed, or rearranged to provide a more aesthetically pleasing fire. Further, the individual translucent artificial embers provide a more three-dimensional, aesthetically pleasing look that resembles real embers because each translucent artificial ember is separate rather than being fused together and to the ember support structure. Alternatively, the translucent artificial embers can be formed into a joined array of artificial embers through adhesion or other connective techniques and placed as a single unit upon the ember support structure.  
         [0043]    Individual translucent artificial embers may come in a variety of shapes and sizes. For example, translucent artificial embers can be generally cubical, spherical, jagged, or irregular in shape. Although different sizes may be used, embers can preferably be sized with average diameters between about ⅛ inch and ¾ inch. It should be understood that other shapes, sizes, and dimensions might be used without departing from the scope of the invention. Further, a combination of differently shaped and sized translucent artificial embers may be used to better simulate a glowing ember bed.  
         [0044]    The translucent artificial embers may be made from a variety of materials. The materials selected to create the translucent artificial embers preferably should perform in high temperatures without foaming or breaking up and also be semi-transparent to allow light to pass through them to simulate glowing. For example, fused silica particles can be used for the translucent artificial embers. The material utilized for the translucent artificial embers in one embodiment of the invention is a fused silica material manufactured by C-E Minerals, located in King of Prussia, Pa., and sold under the Teco-Sil® mark. Teco-Sil® silica is a high purity fused silica with greater than 99% non-crystalline SiO 2 . Less than 1% of Teco-Sil® silica includes Cristobalite. Teco-Sil® silica has a melting point of greater than 3000 degrees Fahrenheit.  
         [0045]    Fused silica is a preferred material for the embers that withstands very high temperatures without foaming or breaking up. Also, fused silica will not bind to the ember support bed during combustion within the combustion chamber. Further, it provides an aesthetically pleasing glow when illuminated because the fused silica diffuses light in a more natural way than other materials. It should be understood, however, that other translucent, high temperature material could also be used to make the translucent artificial embers.  
         [0046]    In one embodiment of the invention, paint or other darkening material can be applied to the surface of a translucent artificial ember. An individual translucent artificial ember can be provided, for example, with paint applied to at least a portion of the surface of the ember. Paint can be applied to the plurality of translucent artificial embers of an ember bed to give the effect of a bed having “cool” ember top and a hot glowing underside. The paint, normally a black or charcoal color, may be applied to a portion of translucent artificial embers or to all of them. Other colorization sources besides paint may also be used, such as, for example, pigmentation that could be added during manufacturing of the translucent artificial embers.  
         [0047]    Referring to FIGS. 1 and 2, the light source  128  is shown positioned beneath the ember support bed  132 . The light generated by light source  128  passes through the ember support bed  132  and onto the translucent artificial embers  126 . Alternatively, the light source can be positioned in any location that provides light to translucent artificial embers, such as disposing the light source on the raised floor. The translucent artificial embers  126  are constructed to pass at least a portion of the light generated by light source  128  through them so as to simulate glowing embers.  
         [0048]    In a preferred configuration, an individual light source  128  is used which includes a light bulb  136  and a light socket  138 . Although the embodiment in FIG. 2 shows a light source including two light bulbs and sockets, it should be understood that one or more light bulbs could be used. Also, more than one light source can be used in the system to enhance the glowing ember effect. Halogen bulbs and ceramic sockets are preferably used to create the light source because these items can withstand the potentially high temperature environment of the fireplace that may exceed 600 degrees Fahrenheit. Halogen bulbs and ceramic sockets are examples of components that can withstand the high temperatures of the fireplace combustion chamber. However, any other suitable light source that can withstand high temperatures may also be used. If the light source is constructed to withstand the high temperatures found in a fireplace, it is not necessary to seal-off the light source from the heat generated in the combustion chamber or to provide other methods to cool the light source. When composed of high temperature materials, the light source can be placed directly within the combustion chamber.  
         [0049]    The light source  128  is shown connected to a control box  140  that has an on/off switch  142  located behind a removable intake panel  144 . Although the control box  140  and on/off switch  142  are provided in this embodiment of the invention, it is possible that the system could be operated without a control box or switch by wiring the simulated electric glowing embers system to operate when the fireplace is in use. Further, other methods, such as a remote-controlled arrangement, could be used to regulate the light sources of the glowing ember system  110 . When the light source  128  is turned on, it provides illumination through ember support bed  132  and thereby illuminates the translucent artificial embers  126 .  
         [0050]    The light source  128  can be controlled by the control box  140  to create a flickering effect and further enhance the simulation of glowing embers. The light source  128  can project a pattern of random flickering light onto the translucent artificial embers  126 , which is non-repetitive and simulates real glowing embers whether or not the gas burner  123  is burning. In some embodiments, it is possible to simultaneous operate the gas burner  123  and the glowing ember system  110  to provide very low heat and create the illusion of an extremely hot fire.  
         [0051]    Shadow curtains  146  and  147  can be used to direct the light generated from the light source through the ember support bed  132  and onto the translucent artificial embers  126 . The shadow curtains  146  and  147  also reduce the amount of stray light that is observed through other openings and apertures in the fireplace. The shadow curtains  146  and  147  can optionally provide support for the ember support bed  132  through engagement with the bottom panel  125  of the enclosure  120 , as shown in FIG. 1.  
         [0052]    In one embodiment of the invention, the glowing embers system  110  is mounted directly below the gas burner  123  and a log set  148 . The gas burner  123  is connected to a gas line  150 . The gas line  150  supplies combustible gas to the burner  123  for producing gas flames  152  that pass up and through a log set  148  that is supported by a burner  123 . The burner  123  can be formed into a log grate  154  that hides structural elements of the burner  123 . Alternatively, the gas burner can be formed into the log set as shown and described in U.S. Pat. No. 6,048,195, incorporated herein by reference. Optionally, the gas line supplying gas to the burner can be hidden from view. For example, a leg of the grate can form a tube for transporting the gas to burner.  
         [0053]    A gas control valve  156  is connected to the gas line  150  and regulates the amount of gas that is permitted to pass to the burner  123  for combustion. Fresh combustion air enters through a coaxial duct  158  and comes down through the fresh air duct  160  and into the combustion air chamber  122 B located between the raised floor  134  and bottom panel  125 . The combustion air can be passed into the chamber  122  through the air gaps  137 . Burning the gas/air mixture within the chamber  122  generates products of combustion. The products of combustion are passed through an exhaust  159  that is defined by the enclosure  120 .  
         [0054]    Referring to FIG. 5, a second embodiment of a direct vent fireplace  500  is shown including a second embodiment of the simulated glowing ember system  510 . The glowing ember system  510  incorporates a gas burner  523  into its construction. Optionally, a second burner can be incorporated into grate  554  or log set  548 . The gas burner  523  includes a burner pan  521  located below an ember support bed  532 . The burner  523  is supplied with combustible gas from a gas line  551 . As illustrated in more detail in FIG. 6, ember support bed  532  includes a plurality of burner apertures  541  that allow combustible gas or a gas/air mixture to pass from through the ember support bed  532  for combustion within the chamber  522 . The plurality of apertures can be arranged and configured in any pattern to provide a desired flame pattern on the top surface of the ember support bed  532 . The diameter of the apertures can be adjusted to vary the size of flames produced from combustion.  
         [0055]    Light source  528  can be disposed within the pan  521  of the burner  523  below the ember support bed  532 . Light generated by the light source  528  passes through the burner apertures  541  and onto translucent artificial embers  526  disposed upon the top surface of the ember support bed. With this arrangement, the light source  528  and translucent artificial embers  526  are manufactured to endure excessive amounts of heat created from being located in close proximity to burner  523 . Teco-Sil® silica is one example of translucent artificial ember material that can withstand the high temperatures encountered with this embodiment. The ember support bed  532  can be supported by downwardly depending support members  546  and  547  attached to the burner and in engagement with bottom panel of the combustion chamber, as shown in FIG. 5.  
         [0056]    Referring to FIG. 7, a third embodiment of a direct vent fireplace  700  is shown including a third embodiment of the simulated glowing ember system  710 . The fireplace  700  includes an enclosure  720  defining a chamber  722  and the glowing ember system  710 . A rear panel  760  and bottom panel  762  of the enclosure  720  and a rear panel  768  and bottom panel  770  of an intermediate enclosure  764  define a fresh air duct  772 . The fresh air duct  772  provides for the passage of fresh air from the exterior of the fireplace to the chamber  722 , as indicated by the arrows “A” on FIG. 7. Fresh combustion air enters through coaxial duct  774  and comes down through the fresh air duct  772 .  
         [0057]    The glowing ember system  710  includes an ember support bed  732 , a lower translucent plate  776 , and a light source  728 . The ember support bed  732  forms at least a portion of a bottom panel  762  of the enclosure  720  and defines a plurality of apertures  741  for the passage of fresh air from the fresh air duct  772  to the chamber  722 . Translucent artificial embers  726  are disposed on the top surface of the ember support bed  732 . The lower translucent plate  776  forms at least a portion of the bottom panel  770  of the intermediate enclosure  764 . The light source  728  is housed below the lower translucent plate  776  and passes light through the fresh air duct  772  and the ember support bed  732  to illuminate the translucent artificial embers  726 . The lower translucent plate  776  and the ember support bed  732  can be constructed of materials, for example, previously described with respect to embodiments of the ember support bed  132  of FIG. 1 and beds  432 A,  432 B, and  432 C.  
         [0058]    Referring to FIG. 8, an embodiment of an electric fireplace  800  is shown including the glowing ember system  810 . The glowing ember system  810  is similar in configuration and operation to the glowing ember system  110  previously described with respect to FIG. 2. In this embodiment, a log set  848  is disposed in chamber  822  defined by enclosure  820 . The log set  848  is mounted directly over simulated electric glowing embers system  810  having translucent artificial embers  826 , an ember support bed  832 , and light source  828  positioned below. The simulated electric glowing embers system  810  in this embodiment functions similarly to the glowing ember systems in the embodiments described above.  
         [0059]    Referring to FIGS. 9 and 10, side and front cross-sectional views of a multisided gas fireplace  900  are shown including the embodiment of the glowing ember system  110  of FIG. 2. Such a direct vent fireplace is of the type shown and described, for example, in U.S. Pat. No. 5,016,609, incorporated by reference.  
         [0060]    Fireplace  900  includes an enclosure  920  that defines a chamber  922 . A portion or all of the enclosure  920  can be used for the combustion of burnable or combustible fuels. Referring to FIG. 10, the glowing embers system  110  is shown disposed within the chamber  922  between a gas burner  923  and a bottom panel  925  of the enclosure  920 .  
         [0061]    The present invention should not be considered limited to the particular examples described above, or to the materials used to describe the various embodiments, but rather should be understood to cover all aspects of the invention as broadly set out in the attached claims. Various modifications, equivalent processes, as well as numerous structures to which the present invention may be applicable will be readily apparent to those of skill in the art to which the present invention is directed upon review of the instant specification.