Abstract:
A prefabricated fireplace enclosure ( 10 ) configured and arranged for compact packaging which comprises first and second side panels ( 20, 21 ), first and second mounting members ( 40, 44 ) securable to the exterior wall of a building, a rear panel ( 22, 23 ) and a bottom panel ( 24 ) adapted for positioning between the first and second side panels, and a roof assembly ( 25 ) adapted for support by the first and second side panels, wherein each of the panels, mounting members and roof assembly are configured and arranged so as to allow for compact packaging and shipment to the construction site in a disassembled condition.

Description:
TECHNICAL FIELD 
   This invention relates generally to fireplaces, and, more specifically, to prefabricated fireplace enclosures. 
   BACKGROUND OF INVENTION 
   In recent years, as many as sixty percent of new homes have been built with at least one fireplace. Many new buildings incorporate one or more fireplaces as well. The advent of “direct vent” fireplaces has allowed for relatively inexpensive installation of new fireplaces in new and existing homes and structures. Traditional masonry work, on the other hand, has become prohibitively expensive and time consuming for many. 
   Fireplace enclosures which surround fireplaces are typically built by contractors on site with the same materials which form the exterior of the home or building, e.g. wood, composites and siding. Therefore, in addition to building a wood or composite frame, insulation, refractory lining and/or masonry work may be required before a fireplace may be installed in a fireplace enclosure. Such additional work must be performed at the construction site, with associated labor costs, and often takes days to complete. 
   It is estimated that more than seventy-five percent of all fireplaces installed today are factory-built and shipped to the construction site. Most fireplaces shipped are direct vent fireplaces which vent directly outside, so there is no need for a traditional chimney or masonry. In addition, they may be installed inexpensively, without the use of skilled craftsmen. “Rear vent, direct vent” fireplaces vent from the rear of the fireplace, collecting combustible air from outside and pumping the by-products of burning gases outside. “Top vent, direct vent” fireplaces vent from the top of the fireplace using the same principles. Approximately eighty percent of new direct vent fireplaces are rear vent, while twenty percent are top vent. A “B-vent” system is a top vented system that uses room air for combustion. Some direct vent systems operate more efficiently when the vent termination is above the roof line of the associated home or building. 
   Fireplace enclosures which project outward from an associated living or office space, for example, require some method of support. This is typically accomplished by unattractive bracing or reinforcement, expensive masonry or concrete work, or the extension of a support member into the associated living or office space, (e.g., a support member extending four feet inside to support a two-foot deep enclosure). In addition, existing fireplace enclosures often require rerouting of mechanical, electrical and/or plumbing features. 
   Prior art discloses prefabricated framed fireplaces (e.g., U.S. Pat. No. 6,374,822 (Lyons, et al.)) which provide a fireplace box with an attached surrounding framework of building materials which becomes a permanent part of the wall or structure to which it is attached. The prior art, however, does not provide a fireplace enclosure adapted for compact packaging or shipping in knock-down condition. Nor does it disclose a modular fireplace enclosure which is adjustable and flexible in terms of height. For example, some top vent, direct vent systems, either for cosmetic purposes or for efficiency, require a fireplace enclosure or flue which extends upward along a substantial portion of the exterior wall of the house or building in which the fireplace is installed. The present invention solves this problem by providing stackable, essentially modular side and rear panels, whereas the prior art discloses a one-piece construction of parts integrally molded together. 
   In addition, the prior art requires a rough opening of substantially the same size as the fireplace box, whereas the present invention, because it is secured to the exterior wall of the structure, from the outside, has no such limitation. In addition, the prior art, because it includes brackets and/or flanges which connect to the interior of the associated structure, must be installed, at least in part, from the interior of the structure. The prior art limits access from the exterior, resulting in difficulty or inconvenience in installing associated gas and/or electric lines. Among other things, the present invention diminishes or eliminates such inconvenience and diminishes or eliminates the need to reroute such items as electrical and plumbing lines and mechanical members. 
   There exists a need for a simple, self-supported fireplace enclosure which is prefabricated and capable of being shipped in knock-down or disassembled condition by standard methods such as UPS, FedEx and U.S. Mail; which may be assembled quickly and efficiently at the construction site without the need for skilled contractors or additional materials such as insulation, Sheetrock or bracing members; which may be assembled from the exterior of the associated structure; which may be used in conjunction with a wide variety of fireplaces available to the public; which provides for variable height by stacking to accommodate various styles of fireplaces and configurations; and/or which allows efficient access from the exterior of the associated home or building to electric and gas lines. 
   DISCLOSURE OF THE INVENTION 
   With parenthetical reference to the corresponding elements or portions of the disclosed embodiment, merely for purposes of illustration and not by way of limitation, the present invention provides an improved fireplace enclosure, which is prefabricated and configured and arranged for simple and compact packaging and delivery to the construction site. The fireplace enclosure may be installed at the construction site quickly and efficiently, without the need for additional bracing, Sheetrock or insulation, and without the need for skilled craftsmen or experienced contractors. If the home or building to which the fireplace enclosure will be attached has a rough opening to accept a fireplace, the improved fireplace enclosure may be installed in minutes with only a drill and machine screws. Because the fireplace enclosure may be installed piece by piece from the outside of the associated structure, the installer is provided with easy access to gas and electric lines. 
   One aspect of the invention provides a prefabricated fireplace enclosure ( 10 ) adapted for compact packaging and connection to an exterior supporting wall of a structure, having a first side panel ( 20 ) and a second side panel ( 21 ); first ( 40 ) and second ( 44 ) mounting members securable to the supporting wall for supporting the first and second side panels, respectively; a rear panel ( 22 ,  23 ) and a bottom panel ( 24 ) adapted for positioning between the first and second side panels; a roof assembly ( 25 ) adapted for support by the first and second side panels; wherein each of the panels, mounting members and roof assembly are configured and arranged so as to allow for compact packaging and shipment to the construction site in a disassembled condition. In this aspect of the invention, the resulting fireplace enclosure assembled from the foregoing components forms a part of the exterior of the structure to which it is connected. 
   In another aspect of the invention, the fireplace enclosure includes two upper side panels ( 27 ,  29 ), two upper mounting members ( 30 ,  31 ) securable to the supporting wall for supporting the upper side panels, and an upper rear panel ( 28 ) positioned between the two upper side panels, wherein the upper side panels and upper rear panels are configured so as to be vertically stacked upon the corresponding side panels and rear panels beneath them ( 20 ,  21 ,  22 ). This aspect of the invention provides for adjustment of the height of the fireplace enclosure. In other words, consecutive side and rear panels may be stacked upon each other, for decorative or efficiency purposes, as high as the roof line of the associated home or building. 
   In another aspect of the invention, the upper rear panel has two vertical edge portions ( 28 A,  28 B), a first lateral channel ( 28 C) extending parallel to a first vertical edge portion ( 28 A), and a second lateral channel ( 28 D) extending parallel to a second vertical edge portion ( 28 B), wherein the first lateral channel is adapted to receive the first upper side panel, and the second lateral channel is adapted to receive the second upper side panel. 
   Yet another aspect of the invention provides for an upper rear insulation pocket in the upper rear panel which is defined by the exterior wall of the upper rear panel ( 28 E) and an interior surface ( 28 F) with a width shorter than the width of the exterior wall. In another aspect, the upper rear insulation pocket has two vertical edge portions which define lateral channels in the upper rear panel. 
   In another aspect of the invention, the rear panel ( 22 ,  23 ) has two vertical edge portions ( 22 A,  22 B,  23 A,  23 B), a first lateral channel ( 22 C,  23 C) extending parallel to a first vertical edge portion ( 22 A,  23 A), and a second lateral channel ( 22 D,  23 D) extending parallel to a second vertical edge portion ( 22 B,  23 B) wherein the first lateral channel is adapted to receive the first side panel and the second lateral channel is adapted to receive the second side panel. In another aspect, the rear panel includes a rear insulation pocket defined by the exterior wall of the rear panel ( 22 E,  23 E) and an interior surface ( 22 F,  23 F) with a width shorter than the width of the exterior wall. In yet another aspect, the rear insulation pocket has two vertical edge portions which define the first and second lateral channels of the rear panel. 
   In another aspect of the invention, the rear panel comprises a substantially rectangular top portion ( 22 ) and a substantially rectangular bottom portion ( 23 ). In this aspect, the top portion has a height h, the bottom portion has a height substantially equal to h, and the first and second side panels have a height substantially equal to 2h. 
   Another aspect of the invention provides a first ( 40 ) and second ( 44 ) mounting members or brackets, wherein the first and second side panels are adapted to be mounted on the corresponding first and second mounting bracket. In another aspect, the first and second mounting brackets are substantially U-shaped. 
   In another aspect of the invention, the mounting members comprise a horizontal mounting portion ( 42 ,  46 ), a vertical mounting portion ( 41 ,  45 ) and a brace portion ( 43 ,  47 ) which is positioned between the horizontal mounting portion and the vertical mounting portion, and which supports the horizontal mounting portion. 
   In another aspect, the roof assembly ( 25 ) of the present invention comprises a pitched top portion ( 25 A) and two vertical side portions ( 25 B,  25 C) wherein the roof assembly is configured and arranged to be positioned on top of the first and second side panels. In another aspect of the invention, the roof assembly is secured to the first and second side panels with screws (e.g.  25 D,  25 E). 
   Several aspects of the invention provide that adjoining or connected members and panels are secured together with screws (e.g.  48 A,  48 B,  48 C). 
   In another aspect of the invention, a top panel ( 26 ) is provided which may be positioned on top of the first and second side panels, and beneath the roof assembly. In another aspect of the invention, the top panel includes a top insulation pocket defined by a top surface ( 26 A) and an interior surface ( 26 B). In this and many aspects of the invention, the top, rear, bottom and side insulation pockets comprise insulation such as Styrofoam insulation. 
   In another aspect of the invention, the top, bottom, side and rear panels, and the roof assembly, comprise galvanized steel. 
   In another aspect of the invention, the first and second side panels include side insulation pockets defined by the corresponding exterior walls ( 20 A,  21 A) and interior surfaces ( 20 B,  21 B) of the respective side panels. 
   In another aspect of the invention, the bottom panel includes a bottom insulation pocket defined by the bottom surface ( 24 B) and the interior surface ( 24 A) of the bottom panel. In another aspect of the invention, the first and second side panels are adapted to snap into, or interlock with, the lateral channels in the rear panel. 
   In another aspect of the invention, each of the top, bottom, rear and side panels, and the roof assembly, are substantially rectangular. 
   Another aspect of the invention provides a method of assembling a prefabricated fireplace enclosure adapted for compact packaging and connection to an exterior supporting wall of a structure. In that aspect, a first side panel and a second side panel, a first mounting member securable to the supporting wall, a second mounting member securable to said supporting wall, a rear panel and a bottom panel adapted for positioning between the first side panel and said second side panel, and a roof assembly adapted for support by said first side panel and said second side panel, are provided. The mounting members are secured to the supporting wall. The first side panel is secured to the first mounting member, and the second side panel is secured to the second mounting member. In addition, the rear and bottom panels are secured between the first side panel and said second side panel, and the roof assembly is positioned on top of the first and second side panels, whereby the fireplace enclosure is assembled and forms a part of the exterior of the structure to which it is connected. 
   In another aspect, first and second upper side panels, first and second upper mounting members securable to said supporting wall, and an upper rear panel adapted for positioning between said first upper side panel and said second upper side panel, are provided. The first and second upper mounting members are secured to the supporting wall above the first and second mounting members, respectively. The first and second side panels are secured to the first and second upper mounting members, and the upper rear panel is positioned between the first and second upper side panels, whereby the height of the fireplace enclosure may be adjusted. 
   The general object of the invention is to reduce the cost of and time associated with fireplace construction and installation. 
   Another object of the invention is to provide a fireplace enclosure adapted for compact packaging. Another object is to provide a prefabricated fireplace enclosure which is easy and inexpensive to ship, and which may be shipped in knock-down or disassembled condition. Yet another object is to provide a prefabricated fireplace enclosure which is easy to install. 
   Another object is to provide a prefabricated fireplace enclosure which requires no additional insulation, Sheetrock or support. 
   Another object is to provide an essentially modular fireplace enclosure with a variable height to accommodate various types of fireplaces and venting methods. 
   Yet another object is to provide a fireplace enclosure which permits efficient access to and installation of gas and electric lines. 
   These and other objects and advantages will become apparent from the foregoing and ongoing written specification, the accompanying drawings and the appended claims. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of the fireplace enclosure of the present invention. 
       FIG. 2  is an exploded view of the fireplace enclosure of the present invention. 
       FIG. 3  is a front view of the fireplace enclosure of the present invention. 
       FIG. 4  is a side view of the fireplace enclosure of the present invention. 
       FIG. 5  is a perspective view of the fireplace enclosure of the present invention depicted with attached siding, roofing and vent cap. 
       FIG. 6  is a perspective view of the fireplace enclosure of the present invention depicted with upper side and rear panels. 
       FIG. 7  is an exploded view of the fireplace enclosure of the present invention depicted with upper side and rear panels. 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   At the outset, it should be clearly understood that like reference numerals are intended to identify the same structural elements, parts, portions or surfaces consistently throughout the several drawing figures, as such elements, parts, portions or surfaces may be further described or explained by the entire written specifications, of which this detailed description is an integral part. Unless otherwise indicated, the drawings are intended to be read together with the specification, and are to be considered a portion of the entire written description of this invention. As used in the following description, the terms “horizontal”, “vertical”, “left”, “right”, “up” and “down”, as well as adjectival and adverbial derivatives thereof (e.g., “horizontally”, “rightwardly”, “upwardly”, “radially”, etc.), simply refer to the orientation of the illustrated structure as the particular drawing figure faces the reader. Similarly, the terms “inwardly,” “outwardly” and “radially” generally refer to the orientation of a surface relative to its axis of elongation, or axis of rotation, as appropriate. 
   Referring now to the drawings,  FIG. 1  illustrates a preferred embodiment of the invention in perspective view. This embodiment of the fireplace enclosure  10  is attached to the exterior or supporting wall  50  of a home or building and the corresponding framing  51  of the home or building. The embodiment includes a first side panel  20  and a second side panel  21 , a substantially rectangular top portion of the rear panel  22  and a substantially rectangular bottom portion of the rear panel  23 , and a roof assembly  25 . 
     FIG. 2  provides additional detail not depicted in FIG.  1 . In particular, the embodiment includes a first mounting member  40  and a second mounting member  44 , both securable to the exterior or supporting wall  50  for supporting the first side panel  20  and second side panel  21 , respectively. The first mounting member includes a vertical, U-shaped portion  41  securable to the exterior wall of the home with screws  48 A,  48 B, and a horizontal, U-shaped portion  42  supported by a brace  43  for supporting the first side panel  20 . Similarly, the second mounting member includes a vertical portion  45 , a horizontal portion  46  supported by a brace  47 , for supporting the second side panel  21 . 
   In this embodiment, the first side panel includes an insulation pocket defined by the exterior wall of the panel  20 A and the interior surface of the panel  20 B. Similarly, the second side panel includes an insulation pocket defined by its exterior wall  21 A and interior surface  21 B. The top portion of the rear panel  22  is defined by two vertical edges  22 A,  22 B, an exterior wall  22 E and an interior surface  22 F, which define first and second vertical channels  22 C,  22 D. Similarly, the bottom portion of the rear panel  23  is defined by two vertical edges  23 A,  23 B, an exterior wall  23 E and an interior surface  23 F, which define first and second vertical channels  23 C,  23 D. In this embodiment, the top and bottom portions of the rear panel are secured to the first and second side panels  20 ,  21  with screws. In addition, the bottom panel, which is secured to the first and second side panels with screws, includes an insulation pocket defined by the interior surface  24 A and a bottom surface  24 B. 
   The roof assembly  25  includes a top pitched portion  25 A and two vertical side portions  25 B,  25 C. The roof assembly  25  is securable to the exterior surface of the home or building  51  with screws  25 D,  25 E, and rests upon the side panels  20 ,  21  and top portion of the rear panel  22 , to which it is secured with screws. 
   In addition, this embodiment includes a top panel  26  having an insulation pocket defined by a top surface  26 A and a bottom surface  26 B. The top panel is also secured to the first side panel  20  and second side panel  21  with screws. 
   The U-shaped channels on the side of the first side panel and second side panel which face the mounting brackets  40 ,  44  are configured such that the respective channels fit over or snap on the corresponding U-shaped horizontal portion  41 ,  45  of the corresponding mounting bracket or member. The channels in the rear panels  22 C,  22 D,  23 C,  23 D snap on or fit over the corresponding sides of the first side panel  20  and second side panel  21 , and may be mounted or attached with screws. 
     FIG. 3  is a front view of this embodiment which depicts the attachment of the fireplace enclosure to the exterior or supporting wall  50  of the home or building and the framing  51  with a number of screws, e.g.  48 A,  48 B. 
     FIG. 4  is a side view of the fireplace enclosure in this embodiment which shows the attachment of the fireplace enclosure to the exterior or supporting wall  50  of the home or building and framing  51  with a number of screws. 
     FIG. 5  is an illustration of the fireplace enclosure which includes siding  61 , a vent cap  60  and roofing  62  which may be added to the fireplace enclosure after installation of the fireplace enclosure. 
     FIG. 6  is an illustration of another embodiment of the invention which includes first and second top side panels  27 ,  29  and a top rear panel  28  which are stacked upon the corresponding first and second side panels  20 ,  21  and rear panel  22 . As shown in  FIG. 7 , an exploded view of  FIG. 6 , this embodiment includes upper mounting members  30 ,  31  which are U-shaped and stacked upon the corresponding lower mounting members  40 ,  44 . The upper rear panel  28  includes two vertical edge portions  28 A,  28 B, an exterior wall or surface  28 E and an interior surface  28 F, which define vertical channels  28 C,  28 D, which vertical channels snap on or fit around the corresponding upper side panels  27 ,  29 . The upper rear panel may be secured or affixed or attached to the corresponding upper side panels with screws. The described surfaces of the upper rear panel define an insulation pocket which may include Styrofoam insulation, which each of the previously described insulation pockets may include. In addition, the upper side panels  27 ,  29  include insulation pockets defined in the same manner as the insulation pockets in the first side panel and second side panel. 
   Modifications 
   The present invention contemplates that many changes and modifications may be made. For example, other means may be used to secure the side panels to the mounting members, and to secure the mounting members to the supporting wall. The various panels and mounting members may also be manufactured from composite materials or plastics, for example. 
   Therefore, while the presently-preferred form of the improved fireplace enclosure has been shown and described, and several modifications and changes thereof discussed, persons skilled in this art will readily appreciate the various additional changes and modifications that may be made without departing from the spirit of the invention, as defined and differentiated by the following claims.