Abstract:
The artificial embers can generally be used in any gas appliance with a gas fired log set that has a burner and are formed of silicon carbide or alumina. A plurality of the embers are placed loosely on a burner in registry with the flames of the burner in order to produce a simulation of actual glowing embers. The plurality of glowing embers simulates an actual ash bed or coals within the gas fired log set. The glowing artificial embers release a minimal amount of NO 2  and CO emissions while creating a more realistic and brighter glow.

Description:
CROSS-REFERENCE TO PRIOR APPLICATION 
       [0001]    This application under 35 USC § 119(e) claims priority to, and benefit from, U.S. Provisional Application Ser. No. 60/780,259, filed on Mar. 8, 2006, entitled “Artificial Embers for Use in a Gas Fired Log Set,” which is currently pending naming the above-listed individuals as the inventors. 
     
    
     TECHNICAL FIELD 
       [0002]    The present invention relates to gas appliances and particularly to gas appliances that simulate gas fired log sets which have a burner. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0003]      FIG. 1  is a top perspective view of a gas fired log set illustrating the embers of an embodiment of the present invention; 
           [0004]      FIG. 2  is a top perspective view of a pan burner illustrating the embers of the embodiment of  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION 
       [0005]    The artificial embers as depicted in the drawings, function to provide an aesthetically pleasing, simulated ash or coal bed for use in gas fired log sets in gas appliances. The artificial embers may be used in both vented or un-vented fireplace applications and meet ANSI standards regarding combustion requirements for CO and NO 2  emissions. 
         [0006]    As illustrated in  FIG. 1 , a typical gas fired log set  1  may include, but is not limited to, artificial logs  2 , a grate  3 , a rear burner  4 , a pan burner  30  containing a plurality of pan burner ports  32 , a controls and valve assembly  6 , a pilot  7 , and the lava rocks  8  within either masonry, or pre-fabricated fireplaces, or in any other “fireplace” type setting, whether commercial or residential in nature. Artificial logs  2  are typically, but are not limited to, made of ceramic or concrete. The burner assembly comprises of pan burner  30 , rear burner  4 , controls and valve assembly  6 , and pilot  7  and is fueled by natural gas, propane, and in some cases butane. The gaseous fuels typically burn with desired blue and bright yellow flames for creating an aesthetically pleasing burner flame pattern. Also, in order to market these log sets  1  the manufacturers make artificial logs  2  look natural by such methods as painting the log sets in natural wood tones, split wood highlights, and smoked, charred features. Lava rocks  8 , typically made of crushed lava rocks, are placed in front of pan burner  30  and piled on the bottom surface of the fireplace to mimic the simulated natural coal or ash bed. Artificial logs  2  are place on top of grate  3  in an arrangement to mimic stacked natural logs to appear as whole logs or split logs of any desired size, shape, or appearance capable of being manufactured. Artificial logs  2  may also be placed in front of grate  3  and pan burner  30  (not shown) to resemble natural logs that have burned and fell onto the side of the grate. Pan burner  30  is positioned under grate  3  which creates the visual appearance of flames rising up through the front of artificial logs  2 . Rear burner  4  is positioned above pan burner  30 , however it is placed near the rear of logs  2  creating the visual appearance of the depth of the burner flame pattern. The controls and valve assembly  6  are intentionally hidden from view to maximize the realistic scene of gas fired log set  1 . Valve assembly  6  allows for gas to travel through pan burner  30 , rear burner  4 , and pilot  7 . Gas is emitted from a plurality of ports in rear burner  4  and pan burner  30 , wherein pilot  7  ignites the gas which in-turn creates flames. As illustrated in  FIGS. 1 and 2 , gas ports  32  are staggered, but are not limited to, across top surface  31  along the front and middle of pan burner  30 . The flames are intended to pass through, lap over, under, and around at least one artificial log  2  in order to create a natural burner flame pattern. 
         [0007]    Although the artificial logs  2 , grate  3 , rear burner  4 , pan burner  30 , controls and valve assembly  6 , pilot  7 , and lava rocks  8  are shown in one configuration in  FIGS. 1 , that is merely one representation of various configurations that can be used with the artificial embers  20 . There are many useful variations in the combination of size, shape, positions, and quantity of the artificial logs  2 , grate  3 , rear burner  4 , pan burner  30 , controls and valve assembly  6 , pilot  7 , and lava rocks  8  that may be used with artificial embers  20 . 
         [0008]    As illustrated in  FIGS. 1 and 2 , a plurality of artificial embers  20  are placed loosely on a top surface  31  of pan burner  30 , over the pan burner ports  32 . Gas and flames exiting out of ports  32  of pan burner  30 , simulate the dancing or flickering flame of a natural wood or coal burning fire. As the flames exits ports  32 , they in-turn heat artificial embers  20  and cause embers  20  to brightly glow and resemble a natural coal or ash bed. Glowing typically occurs within approximately one second upon being heated by the flame. Since artificial embers  20  glow variably as the flames move on and off embers  20 , the embers  20  will exhibit a flickering effect. This flickering effect closely imitates that of actual embers in a fireplace and adds to the aesthetic properties of embers  20 . 
         [0009]    Although the pan burner  30  and ports  32  are shown in one configuration in  FIGS. 1 and 2 , that is merely one representation of various configurations that can be used with the artificial embers  20 . There are many useful variations in the combination of size, shape, positions, and quantity of a burner and ports that may be used with artificial embers  20 , and which allow the embers  20  to be placed loosely on a burner and simulate actual embers in a fireplace. 
         [0010]    The artificial embers  20  may be formed from a material known as Ceramat®. Ceramat® is produced by SCHOTT North America, Inc. Ceramat® is a product used commercially to produce highly permeable, high-performance burners for gas fireplaces and stoves. Ceramat® is normally manufactured as a dense mat structure made up of silicon carbide (SiC) and/or alumina (Al 2 O 3 ) fibers. The fibers are about 10 to about 30 microns in diameter and welded or bonded together by a CVI or CVD process. 
         [0011]    In order to be used as the artificial embers  20  the commercial Ceramat® mat structure must be subjected to a process of de-lamination. The de-lamination of the Ceramat® mat structure is a labor intensive process. De-lamination begins by cutting the mat structure into a plurality of square pieces, each square being approximately 1.000 to 1.125 inches on a side. A cut square is then pulled apart into thinner layers, typically with the aid of a knife or similar device, to a thickness of approximately one fifth of the original thickness of the mat structure. The typical finished Ceramat® ember  20  is approximately 0.0214 kg/m 2  in weight, has a density of about 0.12 grams/cm 3 , and a thickness of about 0.007 inches. The thickness and density of embers  20  allows the flame from a burner to pass through, substantially maintaining the aesthetics of both the flame and ember  20 . If embers  20  are too dense or too thick the embers will become heat sinks and will not effectively simulate an actual ember bed in a fireplace. 
         [0012]    Ceramat® embers  20  burn cleaner and produce a brighter glow, which in turn translates to lower emissions of CO and NO 2  and a more aesthetically pleasing appearance than conventional synthetic ember materials. Additionally, the diameter of the Ceramat® fibers range from about 10 to about 30 microns, which is outside the respirable range. Fibers smaller than 3 microns are considered to be respirable and damaging to the lungs. The Ceramat® product is a chemically inert, non-combustible material. Since the Ceramat embers  20  are made from a non-combustible material they can be used in either vented or vent-free fireplace applications. 
         [0013]    An example of the CO and NO 2  emissions released during the heating and glowing of Ceramat® embers  20  in one test experiment are described herein. Average measurements in one production unit fireplace, using square shaped embers with one inch sides, resulted in test emissions of: 0.002% NO 2 , 0.0013% CO for a quantity of six Ceramat® embers; 0.002% NO 2 , 0.0035% CO for a quantity of twelve Ceramat® embers; and 0.002% NO 2 , 0.0056% CO for a quantity of twenty four Ceramat® embers. 
         [0014]    It is understood that while certain embodiments of the invention have been illustrated and described, it is not limited thereto except insofar as such limitations are included in the following claims and allowable functional equivalents thereof.