Abstract:
A trimmable surround and methods for creating the surround for a heat generating device. The trimmable surround includes a molded portion having a ceramic fiber and a binder and an attachment portion. A portion of the molded member is removable to alter a size of the molded member. An attachment portion coupled to the molded portion allows attachment of the trimmable surround to the heat generating device.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application claims priority to U.S. Provisional patent application Ser. No. 10/620,297 filed on Jul. 15, 2003 and entitled TRIMMABLE SURROUND FOR A HEAT GENERATING DEVICE, which provisional application is incorporated herein by reference in its entirety. 
     
    
     TECHNICAL FIELD  
       [0002]     The present invention relates to heat generating devices. More particularly, the invention relates to a trimmable surround and a method for creating a modifyable surround for heat generating devices.  
       BACKGROUND  
       [0003]     Fireplaces and other heat generating devices have become increasingly commonplace in homes, businesses, and other buildings. For example, a fireplace provides benefits including the generation of heat as well as an aesthetically-pleasing arrangement of flames, sounds, and smells. A fireplace is typically mounted in a wall of a structure and may include one or more exposed surfaces.  
         [0004]     The exposed surfaces of the fireplace can pose safety issues. For example, because the fireplace produces heat, it is possible for one or more of the exposed surfaces of the fireplace to become heated. In particular, metallic exposed surfaces can become hot during fireplace use. Other surfaces of a fireplace that are typically exposed are surfaces through which the interior of the fireplace is viewed (e.g., a glass panel, door, or mesh screen) and the surround that surrounds the fireplace and provides a transition between the exposed fireplace surfaces and the wall structure.  
         [0005]     The exposed surfaces of the surround may become hot and pose a risk of burns to individuals or damage to objects that come into contact with the surfaces. Current fireplace design fails to adequately provide an apparatus or method to maintain the exposed surfaces of the fireplace surround at a temperature that is safe. Also, a metallic exposed surface of the fireplace may not be as aesthetically pleasing to the consumer or blend into a room&#39;s decor.  
         [0006]     Further, surrounds are often required to cover gaps that may exist between a combustion device, such as a fireplace insert, and the existing structure of the building, such as a wall or masonry. Current fireplace surrounds that are placed over the exposed surfaces of the fireplace can require custom measurement, cutting, and/or preparation by the seller or manufacturer of the surround, are difficult to modify by the consumer after purchase, and, if prepared with a finish prior to shipment to the consumer, may not match the decor surrounding the fireplace once placed over the exposed surface(s) of the fireplace unit.  
       SUMMARY  
       [0007]     Generally, the present invention relates to heat generating devices. More particularly, the invention relates to a trimmable surround and a method for creating a modifyable surround for heat generating devices.  
         [0008]     According to one aspect, the invention relates to a trimmable surround and methods for creating the surround for a heat generating device. The trimmable surround includes a molded portion having a ceramic fiber and a binder, and an attachment portion. The attachment portion is coupled to the molded portion to allow attachment of the trimmable surround to the heat generating device. The trimmable surround may be reduced in size by, for example, cutting or trimming portions of the surround.  
         [0009]     The above summary of the present invention is not intended to describe each disclosed embodiment or every implementation of the present invention. Figures in the detailed description that follow more particularly exemplify embodiments of the invention. While certain embodiments will be illustrated and described, the invention is not limited to use in such embodiments.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]     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:  
         [0011]      FIG. 1  is a front view of an example surround made in accordance with the present invention;  
         [0012]      FIG. 2  is a cross-sectional view taken along line  2 - 2  of the surround shown in  FIG. 1 ;  
         [0013]      FIG. 3  is a front view of a second example surround made in accordance with the present invention;  
         [0014]      FIG. 4  is a back view of the surround shown in  FIG. 3 ;  
         [0015]      FIG. 5  is front/top exploded perspective view of the surround shown in  FIG. 3 ;  
         [0016]      FIG. 6  is a front view of an example fireplace including an example embodiment of a trimmable surround made in accordance with the present invention;  
         [0017]      FIG. 7  is a front/top perspective view of the fireplace and trimmable surround shown in  FIG. 6 ;  
         [0018]      FIG. 8  is a top view of the fireplace and trimmable surround shown in  FIG. 6 ;  
         [0019]      FIG. 8A  is an enlarged view of a portion of the fireplace and trimmable surround shown in  FIG. 8 ;  
         [0020]      FIG. 9  is a front/top exploded perspective view of the fireplace and trimmable surround shown in  FIG. 6 ;  
         [0021]      FIG. 10  is a side view of the fireplace and trimmable surround shown in  FIG. 6  installed within an opening of a wall structure; and  
         [0022]      FIG. 10A  is an enlarged view of a portion of the fireplace and trimmable surround shown in  FIG. 10 . 
     
    
       [0023]     While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example and 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  
       [0024]     The present invention relates to fireplaces. More particularly, the invention relates to a surround for a fireplace that can be easily modified, installed over or adjacent to an exposed surface of a fireplace, and finished as desired by the consumer. While the present invention is not so limited, an appreciation of the various aspects of the invention will be gained through a discussion of the examples provided below.  
         [0025]     Embodiments of the present invention may be used in conjunction with any system or apparatus that ignites a combustible gas to generate a gas flame or any other heat generating device. A non-exhaustive list of such heat generating devices may include fireplaces, grills, stoves, furnaces etc. Other embodiments of the present invention may also be applicable to other heat generating devices such as electric fireplaces, and be applicable to simulated fire display devices. While the example embodiments of the present invention provided below are described in conjunction with an example fireplace insert, the present invention is equally applicable to other systems or apparatuses besides a fireplace that ignite a combustible gas to generate a gas flame or that simulate a flame.  
         [0026]     As used herein, the term “coupled” means any structure or method that may be used to provide connectivity between two or more elements, which may or may not include a direct physical connection between the elements. The terms “exposed panel” and “exposed surface” mean any panel or surface of the fireplace or other device that may heated by heat generated by the fireplace and that is accessible by the operator or user of the fireplace following installation. The phrase “combustion chamber enclosure” may include any enclosure in which flames and/or heat are generated or simulated. The term “surround” means any exposed structural surface that covers or is adjacent to a portion of the fireplace (e.g., “exposed surface”) or structure adjacent thereto.  
         [0027]     Referring to  FIGS. 1 and 2 , front and cross-sectional views of an example embodiment of a trimmable surround  100  are shown. The trimmable surround  100  may be comprised of any material that provides a surface  102  that insulates a user of a fireplace from at least one exposed surface of the fireplace. The trimmable surround  100  includes a molded portion  104  that includes a top portion  106 , and two side portions  108 ,  110 .  
         [0028]     Molded portion  104  can be formed from, for example, inorganic ceramic fibers and a binder. Molded portion  104  can be formed by any known molding technique, such as, for example, compression molding, vacuum forming, or casting techniques. Exemplary molding compositions and forming techniques are described in pending United States Publication No. US-2003-0049575-A1, which is incorporated herein by reference in its entirety. Additional exemplary molding compositions and forming techniques are described in U.S. Pat. Nos. 5,941,237; 5,996,575; and 6,170,481, which patents are incorporated herein by reference in their entirety.  
         [0029]     The top portion  106  and two side portions  108 ,  110  can define an opening  111  that typically corresponds to the dimensions of a glass panel that allows viewing into the fireplace. For example, opening  111  is approximately 34 inches wide along dimension W and 26 inches high along dimension X. These dimensions can correspond to the opening of a number of gas fireplace inserts. For example, the dimensions of opening  111  can be used with a Hearth &amp; Home Technologies (Lakeville, Minn.) fireplace insert sold under the names of FB-GRAND. The side portions  108 ,  110  of trimmable surround  100  can have a width Y of about, for example, 3-10 inches and preferably has a width of about 7 inches. The top portion  106  can have a dimension Z of about, for example, 3-10 inches and preferably has a width Z of about 6 inches. Trimmable surround  100  can be formed in any other desired size, shape and configuration to the configuration shown in the Figures. For example, trimmable surround can be formed and sized to cover exposed surfaces of wood stoves or other combustion devices.  
         [0030]     Surround  100  can be attached to a combustion device using, for example, screws, bolts, or high temperature adhesives, and may further require placing the surround in front of the combustion device, sizing the surround to press fit into an opening, or utilizing other attachment devices, such as the apparatus disclosed in  FIGS. 3-5 .  
         [0031]     Referring to  FIGS. 3-5 , another embodiment of a trimmable surround  200  is shown. The trimmable surround  200  includes a molded portion  204  having a top portion  206 , and two side portions  208 ,  210 . The top portion  206  and two side portions  208 ,  210  can define an opening  211  having dimensions A, B (see  FIG. 4 ), which dimensions may be similar to dimensions Y, Z for surround  100 .  
         [0032]     Trimmable surround  200  also includes an attachment portion  212 . The attachment portion  212  includes a right bracket  214 , left bracket  216 , and a top bracket  218 . Optionally included is a bottom bracket  217 . Although shown a multiple parts, alternatively, attachment portion can be constructed as a single unit. Flanges  220 ,  221  extend from a bottom portion  222  of each of the right and left brackets  214 ,  216 .  
         [0033]     Top bracket  218  includes air holes  224 ,  225 ,  226 ,  227  that allow for the circulation of heated room air. Air holes  224 ,  225 ,  226 ,  227  are only one example of a construction that will allow for the return of air into the room in which a fireplace is located. Alternatively, a single air hole can be used, or if no circulation of room air is desired, the air holes can be eliminated.  
         [0034]     As shown in  FIG. 4 , the attachment portion  212  can be screwed into a back surface  228  of the molded portion  204 . Alternatively, attachment portion  212  can be coupled to the molded portion through other means, such as, for example, bolting, adhering, or forming the attachment portion into the molded portion during the molding process. The attachment portion  212  allows an installer to couple the molded portion  204  to a combustion device.  
         [0035]     Trimmable surrounds  100 ,  200  can be manipulated in any number of ways. In one method, a standard size surround is used and can be trimmed by the consumer as desired. The consumer purchases the trimmable surround, such as surrounds  100 ,  200 , with the intention of trimming the surround to a size that fits a particular fireplace opening or exposed surface that is to be at least partially covered with a finished surround.  
         [0036]     A consumer can trim a surround to a desired size according to the following example steps. After purchasing a trimmable surround (such as  100 ,  200 ) of a desired size, shape, or dimension, the consumer can utilize a template, which is either supplied by the manufacturer or created by the consumer, to trace a combustion device opening in which a combustion device is disposed. After tracing the combustion device opening, the consumer cuts the template and verifies that the finished template fits within the combustion device opening. In some embodiments, the template may be cut to a size larger or smaller than the combustion device opening so that the trimmed surround properly overlaps or resides adjacent to the combustion device opening as desired.  
         [0037]     Once a final template is created, the inside opening of the template is aligned with an opening ( 111 ,  211 ) of the trimmable surround ( 100 ,  200 ) on a front surface of the trimmable surround ( 100 ,  200 ). The consumer then traces around the template to mark off the size of the combustion device opening. The consumer next cuts or removes the excess portions of the trimmable surround ( 100 ,  200 ) off using a jig saw, skill saw, hand saw or other cutting device. Cutting may be done along, for example, inner edges  203 ,  205  of the side portions  208 ,  210 , or cutting may define the edges  203 ,  205 . The consumer can leave the template in place on the front surface ( 103 ,  203 ) of the trimmable surround ( 100 ,  200 ) during the cutting process. Alternatively, the template can be removed prior to cutting the trimmable surround ( 100 ,  200 ). In further embodiments, the surround may be constructed so that the size modifications to the surround can be made by breaking, bending, or otherwise removing predetermined sections, strips, or other pieces from the surround.  
         [0038]     After cutting the trimmable surround ( 100 ,  200 ), the consumer can paint or stain the outer surface facing (e.g., surface  102 ) of the surround to match the surrounding decor of the room or fireplace structure. Staining a compression molded fiber material may provide a marbleized or other specific look to the trimmable surround depending on the fiber material and method of molding. After preparing the finish on the trimmable surround ( 100 ,  200 ), the surround can be installed onto the fireplace, insert, stove, or other heat generating device.  
         [0039]     Trimmable surround can also be manipulated in other ways. For example, patterns, designs, initials, or other decorative modifications can be made to the trimmable surround ( 100 ,  200 ) prior to or after installation in the fireplace opening. Functional modifications can also be made. For example, holes or openings can be created in the trimmable surround ( 100 ,  200 ) to allow for air passage around the fireplace. These types of modifications can be made to the surround before or after the surround is installed depending of the type of modification being made.  
         [0040]     Referring to  FIGS. 6-9 , trimmable surround  200  is shown coupled to a combustion device  250  (heat generating device), such as a fireplace insert. Combustion device  250  is illustrated including an outer enclosure  252  having a front panel  254 , top panel  256 , back panel  258 , and two side panels  260 ,  262 .  
         [0041]     Coupling of the trimmable surround  200  to front panel  254  can cover gaps, such as gap R shown in  FIG. 10 , between an existing structure  264 , such as a wall or masonry, and the combustion device  250  being covered. As shown in  FIG. 10 , the trimmable surround  200  can been sized to fit within an opening  279  in a wall  265  of the existing structure  264 . For example, if a height of the trimmable surround  200  is too tall to fit within the opening of the wall  265 , an upper portion  281  of the surround  200  can be trimmed to lower the surround and allow the surround to fit within the opening  279  in the wall  265 . Likewise, side portions  208 ,  210  can be trimmed on outer side edges  207 ,  209  (see  FIG. 9 ) as necessary to conform to the opening in a wall  265 , or can be trimmed on inner edges  203 ,  205  (see  FIG. 5 ) to properly cover the exposed surface  251  of the combustion device  250 . Similar modifications can be made to the top portion  106  and side portions  108 ,  110  of trimmable surround  100 .  
         [0042]     The combustion device  250  may generally function to ignite combustible gas provided from a combustible gas source to create a gas flame. For example, a burner (not shown) can be positioned within the combustion device  250 , which generates heat that increases the temperature of an exposed surface and the outer enclosure  252 . Often, when a surround is formed of a metal material, the exposed surface is heated to a temperature that can cause injury to an individual who touches the surface unless all or a portion of the exposed surface is isolated from the heat to lower the temperature of the exposed surface.  
         [0043]     As shown in  FIGS. 6-10 , utilization of trimmable surround  200  provides a barrier between the user of the combustion device  250  and the exposed surface  251  (see  FIG. 9 ), and minimizes the amount of the exposed surface  251 . This type of barrier may be particularly relevant when surface  251  includes a metal or other high heat conductive material. Trimmable surround  200  may be composed of a ceramic fiber and a binder, which is a non-metallic material. Another exemplary non-metallic material for surround  200  is fiberglass. In prior surround systems, metal is primarily used as the material for covering gaps between the combustion device  250  and the existing wall or masonry of a structure.  
         [0044]     Room air may be heated as it travels around the outer enclosure  252 . Optionally, a blower (not shown) can be used for moving room air into and out of an area surrounding the combustion device  250 . An exhaust  266  exhausts combusted air from the combustion device  250 . The combustion device  250  may also include an air intake  268  that facilitates bringing fresh combustion air into the combustion device  250  for combustion.  
         [0045]     Screws, bolts, high temperature adhesives, or other attachment devices can be utilized to attach the trimmable surround  200  to the combustion device  250 . For example, the trimmable surround  200  may be coupled to device  250  with mounting screws that pass through flanges  220 ,  221  and into lower portions  269 ,  270  of the combustion device  250 . As shown best in  FIGS. 8A and 10A , the top bracket  218  can include slots  271  that receive mounting tabs  273  of the combustion device  250 .  
         [0046]      FIGS. 6-10  show a combustion device in one configuration. Other configurations are also possible. For example, the present invention may be applicable to any prefabricated gas fireplace such as a direct vent, a universal vent, a B-vent, a horizontal/vertical-vent, a dual direct vent, or a multisided unit. For a multi-sided fireplace such as the one disclosed in U.S. Pat. No. 5,016,609, incorporated herein by reference in its entirety, a single surround formed from a single molded piece, can be placed over the multiple exposed sides of the multi-sided unit. Alternatively, a multiple number of panels can be placed over each exposed side of the multi-sided fireplace unit. The present invention may also be applicable to free standing wood stoves and wood inserts.  
         [0047]     The present invention may also be applicable to other combustible gas fireplace systems, as noted above, as well as any other fireplace or device that generates heat such as a simulated electric fireplace or solid fuel-burning fireplace. For example, the simulated electric fireplace may be constructed within the outer enclosure  252 . The simulated electric fireplace can include several electrical components such as a simulated ember bed, lights, a heat source, and a blower.  
         [0048]     As previously noted, the present invention is applicable for use with fireplaces of varying sizes and shapes. The surround can be trimmed and modified as needed to fit a given fireplace configuration. For example, if a fireplace includes an arch-shaped front panel, an upper portion of the opening of the surround can be cut to conform to the arch-shaped front panel. If such a fireplace is used, one or more pieces of the attachment portion, such as the top bracket, can be removed if necessary and only the right and left brackets used to couple the surround to the fireplace.  
         [0049]     The example surrounds disclosed herein can be used to finish a new fireplace installation or to refinish a fireplace that has been previously installed. For example, existing fireplaces that include metallic surrounds can be refinished using surrounds  100 ,  200  disclosed herein. If an existing metallic surround is to be replaced, the metallic surrounds can be removed prior to installation of the new surround, or the new surround can simply be placed over the existing metallic surrounds.  
         [0050]     The present invention should not be considered limited to the particular examples or materials described above, but rather should be understood to cover all aspect of the invention as fairly 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.