Electric fireplace lighting system

A lighting system for an electric fireplace, and a fireplace assembly including such system, may include a plurality of logs arranged in different orientations and in different rows. Some of the logs may include a substantially planar surface facing forwards. A front projector may project a lighting effect onto the logs, including the substantially planar surfaces, and a rear projector may project a lighting effect onto a non-transparent screen positioned behind the plurality of logs. The lighting system desirably provides a realistic three-dimensional flame effect in conjunction with a log set having a natural, split-log appearance. Other features may be included to enhance the lighting system, including internal lights in the logs and in an ember bed, as well as coloration of the logs to enhance the lighting effects and the natural appearance of the logs.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to Chinese Patent Application No. 201610306066.2, filed May 10, 2016, the disclosure of which is hereby incorporated by reference.

BACKGROUND OF THE INVENTION

Electric fireplaces, which simulate the look of wood-burning fireplaces, are known. Lighting effects may be used in these fireplaces to mimic aspects of illumination patterns that are observed in real, wood-burning fires. The present invention includes an improvement of such lighting effects and enhances the appearance of a simulated fire.

BRIEF SUMMARY OF THE INVENTION

One aspect of the present invention provides an electric fireplace assembly. The electric fireplace assembly may have a front portion and a rear portion. According to this aspect of the invention, the electric fireplace assembly may include a plurality of logs, a non-transparent screen, a front projector, and a rear projector. At least one of the logs may have a substantially planar surface facing the front of the fireplace. The non-transparent screen may be positioned behind the plurality of logs toward or at the rear of the fireplace. The front projector is desirably for projecting light onto at least a portion of the substantially planar surface of one or more of the logs to provide the appearance of a burning log. The rear projector is desirably for projecting light onto the screen behind the logs to provide a further appearance of a burning log.

In accordance with further aspects of the invention, multiple front projectors may be provided. Moreover, multiple projectors of the fireplace assembly may be synchronized. For example, the front projector may include a front light source and a rotatable front spinner, and the rear projector may include a rear light source and a rotatable rear spinner. The front and rear spinners may be configured to reflect light from the respective front and rear light sources. In accordance with one aspect of the invention, the fireplace assembly may include a rotation control system for synchronizing rotation of the front and rear spinners.

In accordance with yet further aspects of the invention, at least two of the logs extend along different axes, which axes may be transverse to one another. Additionally, or alternatively, the axis of one of the logs may be positioned in front of the axis of another one of the logs. The front projector may be configured to project light onto at least a portion of an ember bed positioned below the logs. At least one of the logs may include a lighting source within it. The substantially planar surface of at least one of the logs may have a different color than other portions of that log.

Another aspect of the present invention provides an electric fireplace assembly. The electric fireplace assembly may have a front portion and a rear portion. According to this aspect of the invention, the electric fireplace assembly may include a plurality of logs and a front projector. The plurality of logs may include a first log extending along a first axis and a second log extending along a second axis. The first log and its first axis may be positioned closer to the front portion of the fireplace assembly than the second log and its second axis. The front projector is desirably for projecting light onto at least a portion of each of the first and second logs to provide the appearance of burning logs.

In accordance with further aspects of the invention, multiple front projectors may be provided. A rear projector may also be provided for projecting light onto a screen positioned toward or at the rear portion of the fireplace assembly, in order to provide the appearance of burning logs. In accordance with some aspects of the invention, that screen may be non-transparent. Moreover, multiple projectors of the fireplace assembly may be synchronized. For example, the front projector may include a front light source and a rotatable front spinner, and the rear projector may include a rear light source and a rotatable rear spinner. The front and rear spinners may be configured to reflect light from the respective front and rear light sources. In accordance with one aspect of the invention, the fireplace assembly may include a rotation control system for synchronizing rotation of the front and rear spinners

In accordance with other aspects of the invention, the first log of the plurality of logs may have a first substantially planar surface facing the front of the fireplace assembly, and the front projector may be configured to project light onto at least a portion of that first substantially planar face, in order to provide the appearance of a burning log. Moreover, the first substantially planar surface of the first log may have a different color than other portions of that log. The second log of the plurality of logs may also have a second substantially planar surface facing the front of the fireplace assembly, and the front projector may be configured to project light onto at least a portion of the second substantially planar surface, in order to provide the appearance of a burning log. The front projector may be configured to project light onto at least a portion of an ember bed positioned below the logs. At least one of the logs may include a lighting source within it.

The electric fireplace assembly in accordance with any of the above aspects may further include a third log extending along a third axis. That third log may be positioned adjacent to the first log, such that the first and third logs define a first row positioned toward the front of the fireplace assembly with respect to the second log. The third axis of that third log may be transverse to the first axis of the first log. The electric fireplace assembly may further include a fourth log extending along a fourth axis. That fourth log may be positioned adjacent to the second log, such that the second and fourth logs define a second row positioned toward the rear of the fireplace assembly with respect to the first row. The fourth axis of that fourth log may be transverse to the second axis of the second log.

DETAILED DESCRIPTION

FIG. 1illustrates an electric fireplace1in accordance with an embodiment of the present invention. The electric fireplace1may be a freestanding component or it may include an insert configured to be received within another structure, such as a piece of furniture (e.g., a piece of cabinetry) or an opening in a wall of a building, or even within the firebox of a traditional fireplace. The electric fireplace1includes a housing3defining an interior volume. The front5of the electric fireplace1includes a main opening7. An at least partially translucent or transparent structure, such as a window pane9may be positioned in the opening7.

The electric fireplace1may include controls10for controlling the operation of the fireplace1. Also, the electric fireplace1may also include another opening with a grill11arranged above the main opening7, to direct heat out of the electric fireplace1to heat the area located in proximity to the fireplace. In that way, the electric fireplace1may function as a heater and may provide at least some of the heat provided by a wood or other fuel-burning fireplace. As shown inFIG. 1, the controls10and the grill11may both be located on the front5of the fireplace1, for example above the main opening7.

Inside the interior volume of the electric fireplace1is a log set12, which may include one or more logs13positioned on a grate15. The logs13are preferably artificial, although they may be real wood logs, and the logs13may be structured so as to mimic real wood logs. Typical materials for the logs13include polymers, ceramic, metal, glass and wood (although other materials may also be used), and the logs13may be colored (e.g., painted, dyed, etc.) so that their exterior surfaces mimic the appearance and color of real wood logs.

As shown inFIG. 2, an ember bed16is preferably arranged below the log set12, which can create the appearance of glowing embers and/or burned ash in a traditional, wood-burning fireplace. The ember bed16may be constructed of polymer, ceramic, metal, glass, or other material, and may be colored so that its exterior surface appears as real glowing embers and/or burned ash. Behind the log set12, at the rear17of the housing3, is a rear wall19. The rear wall19preferably has a solid (non-transparent) appearance and may include a design for visual interest, such as a design which creates the appearance of the inside of a traditional fireplace. For example, as shown inFIG. 1, the design may include a brick pattern. Other interior walls20may also include the same or different designs, as shown in the embodiment illustrated inFIG. 11B.

Turning to the cross-sectional view inFIG. 2, a heater21is arranged near the top23portion of the housing3. The heater21may be a convection heater that blows heated air out of one or more openings in the electric fireplace3, such as the grill11on the front5illustrated inFIG. 1. The heater21may include a fan, such as a centrifugal fan or blower25, for moving air past one or more heating elements27to heat the air before it exits the grill11. The heater21need not be a convection heater, however, and any other suitable heater for providing desired warmth to the area located in proximity to the fireplace may be used, such as a radiant heater.

Also inside the housing3of the electric fireplace1, is a lighting system that simulates aspects of the illumination patterns observed in wood or other fuel-burning fires. For example, the lighting system may include a rear projector for projecting lighting effects onto a screen behind the log set12. Alternatively, the rear wall19may function as such a screen. The rear projector may include a rear light source29and a rear spinner31. As shown inFIGS. 4-5, the rear light source29may include an array of lights33, such as LEDs, supported by a supporting structure35(such as a printed circuit board). Other types of lights may be used without limitation, however, including, for example, incandescent, fluorescent and halogen lights. The lights may be colored (or they may have multiple colors) in order to mimic the colors emitted by a real, fuel-burning fire. As also shown inFIGS. 4-5, the rear spinner31includes a central axle37that is supported at least at one end by a support39, but desirably has supports39at each end, and is rotationally driven about the axle37by a motor41. A plurality of strips43of at least partially reflective material radiate outwardly from the axle37along its length. Those strips43may each extend outwardly from the axle37along a variety of twisting and/or undulating paths, and/or their peripheral edges may have a variety of curving profiles.

As shown inFIG. 3, the rear light source29and rear spinner31are desirably arranged so that light emanating from the rear light source29reflects at least partially from the strips43of the rear spinner31and is projected onto the rear screen19, which may be non-transparent. By rotating the rear spinner31about its central axle37, the projected light on the rear screen19will desirably move and/or flicker similarly to light emanating from a real fuel-burning fire. A flame-shaping template45may also be provided between the rear spinner31and the rear screen19in order to shape the light projected onto the rear screen19. As shown inFIG. 6, that template45may be a panel having flame-shaped cutouts47that permit light to pass through them.

The lighting system may also include a front projector for projecting lighting effects onto one or more of the logs13and/or the ember bed16. The front projector may include a front light source49and a front spinner51. As shown inFIGS. 4-5, the front light source49, like the rear light source29, may include an array of lights53(such as LEDs) supported by a supporting structure55(such as a printed circuit board). As with the rear light source29, other types of lights may be used in the front light source49without limitation, including, for example, incandescent, fluorescent, and halogen lights. The lights may also be colored, and they may have multiple colors, in order to mimic the colors emitted by a real, wood or other fuel-burning fire. As also shown inFIGS. 4-5, the front spinner51includes a central axle57that is supported at least at one end by a support59, but desirably has supports59at each end, and is rotationally driven by a motor61. The central axle57includes a plurality of light-reflecting strips63of at least partially reflective material along its length. Those strips63may have similar or identical shapes to those discussed above in connection with the rear spinner31.

In one embodiment, as shown inFIGS. 2-5, the front and rear spinners have similar structures, but the front spinner51has a smaller diameter (as defined by the radial extent of the strips63) than that of the rear spinner31, and the central axle57of the front spinner51may be positioned closer to the bottom65of the fireplace housing3than that of the rear spinner31. As shown inFIG. 3, the front light source49and front spinner51are desirably arranged so that light emanating from the front light source49reflects at least partially off of the strips63of the front spinner51and is projected onto the logs13and/or ember bed16. By rotating the front spinner51about its central axle57, the projected light on the logs13and/or ember bed16will desirably move and/or flicker similarly to light created by a wood-burning fire.

A log set12in accordance with preferred embodiments of the present invention desirably includes a plurality of logs13, such as four logs shown inFIG. 1. Desirably, at least one of those logs13includes at least one substantially planar face67extending along its longitudinal axis such that the log13mimics a natural log which has been split in the longitudinal direction. Preferably, the log13is oriented such that the substantially planar face67faces in a generally forwards direction towards the front5of the fireplace1. In that way, desirably the planar face67acts somewhat like a projection screen that it is better adapted to receive the light projected from the front spinner51than the more curved surfaces69of the other portions of the log13. The substantially planar face67of the log13would preferably not define a completely flat plane, but rather would extend generally along a plane, particularly in comparison to the more curved surfaces69of the other portions of the log13. Indeed, like natural logs that have been split along their longitudinal dimensions, the substantially planer face67would preferably at least have linear ridges extending in the longitudinal direction, similar to the longitudinal fibers of a natural split log. Moreover, the surface67would also preferably deviate at least slightly from the plane along which it extends at one or more locations, so as to resemble the imperfections of a natural split log face. Furthermore, to better resemble a natural split log, the log13is desirably colored (e.g., painted, dyed, etc.) differently in different locations. For example, the substantially planar face67may include a different color than the color of the more curved surfaces69. In that way, the log13may mimic the natural color differences in natural logs, which often have outer, curved surfaces that are covered with bark having a different color than the color of the interior of the log that is exposed when the log is split. For some logs, the interior is a lighter color than the color of the bark. For other logs, such as those from birch trees, a split log may include an interior with a beige tone while the exterior curved surface is covered with a white bark. Regardless of the color difference, the planar face67of the log13may function better as a projection screen for the light projected from the front spinner51than the more curved surfaces69of the other portions of the log13. In some instances, logs that have a lighter color on the substantially planar face67may more effectively display the light projected onto it by the front spinner51.

Desirably, the logs13of the log set12in accordance with preferred embodiments of the present invention extend at different angles to one another. For example, as shown in the embodiment of the log set12illustrated inFIG. 1, as well as the embodiment of the log set illustrated inFIGS. 9-10, the logs13extend along longitudinal axes that are transverse to one another. Alternatively, or additionally, the logs13may be generally arranged in multiple rows. For example, as shown in the embodiment ofFIGS. 9-10, the log set12may include two logs13in a first row71which is positioned more towards the front5of the fireplace1(e.g., closer to transparent pane9) than the logs13in a second row73. Desirably at least one log in each row may be a split log having a substantially planar face67, with the face67facing in a generally forwards direction towards the front5of the fireplace1, as discussed above. For example, all of the logs13in the log set12may have such forwardly facing substantially planar faces67. The logs13in one or more rows may also be transverse to other logs13in the same row. For example, as shown inFIGS. 9-10, the two logs13in the first row71are oriented so that their substantially planar faces67angle slightly towards one another. Similarly, the two logs13in the second row73are oriented so that their forward-facing planar faces67are also angled slightly towards one another.

Desirably, the above-discussed features of the preferred embodiments of the invention, and particularly combinations of multiple such features, give the log set12and the simulated fire a more natural, three-dimensional appearance. In that regard, having a log set12in which at least one of the logs13has a forwardly-facing, substantially planar face67for receiving flame-mimicking light projected from the front projector, particularly in combination with a non-transparent rear wall19or screen behind the logs13that receives flame-mimicking light projected from the rear projector, desirably provides a realistic three-dimensional flame effect in conjunction with a log set having a natural, split-log appearance. Moreover, providing an arrangement of a plurality of logs13in the log set12that extend in different, transverse orientations, and also are positioned in front of or behind one another, will add to the three-dimensional flame effect when the front projector projects flame-mimicking light on multiple ones of those differently positioned logs13.

To further add to the lighting effects and increase the realism of the simulation, one or more of the logs13in the log set12may be at least somewhat translucent and may include one or more internal lights such that the log(s)13appear to glow. The ember bed16may similarly be at least somewhat translucent, and one or more lights may be included below the ember bed16such that it appears to glow as in the case of a real wood fire.

Various steps in the assembly of one embodiment of the present invention are illustrated inFIGS. 4-10. For example, a baseplate75to be positioned at the bottom65of the housing3may first be assembled with the rear light source29, rear spinner31, front light source49, and front spinner components51, as shown inFIGS. 4-5. Then, a flame-shaping template45may be provided to the rear of the rear spinner31, as shown inFIG. 6. A panel77may then be provided between the rear spinner31and the front light source49, which panel77may be attached along its top end79to the top81of the flame-shaping template45, as shown inFIG. 7. In that way, the panel77and flame-shaping template45may define an enclosure78around the rear light source29and rear spinner31, as shown inFIG. 3. In order to reduce errant reflections and/or prevent the light of the rear light source29from escaping towards the front5of the fireplace1past the panel77, the panel77is desirably dark colored, non-reflective, and/or does not transmit light through it. A preferred material for the panel77may be rubber. After the panel77is secured, the ember bed16may be positioned over the panel77, as shown inFIG. 8. The log set12may then be positioned on top of the ember bed16and the enclosure78, as shown inFIGS. 9-10. The baseplate75with the above-discussed components attached to it may then be positioned within the housing3of the electric fireplace1.

In operation, the rear projector may be operated to project flame shaped light81on the rear screen19, as shown in the illustrations ofFIGS. 12A-B, and that light81may flicker and/or move, for example based on the rotation of the rear spinner31, as discussed above. As shown inFIG. 11, the reflected light from the illuminated strips43of the rear spinner31may pass through the flame-shaping template45before being projected on the rear screen19. As also shown inFIGS. 12A-B, light83may be projected onto the substantially planar surfaces67of the logs13in the log set12, which light83may also flicker and/or move, as discussed above, in order to simulate a real wood-burning fire.

In accordance with other embodiments of the invention, the lighting system may include multiple front projectors. Some such embodiments may include multiple rows of front projectors, for example with each row corresponding to a respective row of logs. That is, each row of front projectors can be positioned such that the light from the projector (e.g., the reflected light from the spinner) is directed onto its own associated row of logs. Such embodiments may provide added depth to the flame simulation. In other such embodiments, multiple front projectors may be provided with at least one being associated with its own log. For example, particularly where multiple logs within a particular row are significantly angled with respect to one another, multiple front projectors may be provided where each projector is associated with its own log, so as to provide optimal lighting projection onto each log. Each such projector may, for example, be aligned with the respective log, such that the spinner and the light source extend substantially parallel to the longitudinal axis of the associated log.

In accordance with yet further embodiments of the invention, multiple lighting projectors may be coordinated, e.g., such that it looks like a flame starts on one of the logs and then continues up onto the rear screen. For example, a rotation control system may synchronize the rotation of the front spinner51and rear spinner31so as to create that or other lighting effects. One example of such a rotation control system may include a physical interconnection (e.g., a chain or belt drive) between the front spinner51and the rear spinner31. In such an example, a pulley on each axle37,57of the rear and front spinners31,51, respectively, may be interconnected with a belt, or a sprocket on each axle of the front and rear spinners may be interconnected with a chain, so that both axles rotate together. In such an embodiment, one of the front or rear motors41,61may be eliminated, such that both spinners31,51are controlled by a single motor via the interconnecting belt or chain. Alternatively, both front and rear motors41,61may be eliminated, and a single motor may be provided that drives the interconnecting belt or chain directly, so as to induce synchronized rotation of both spinners31,51. Another example of a rotation control system may include electronic control of the rotation of the front and rear spinners51,31. For example, the control system that controls each motor41,61may be programmed to synchronize the rotation of both spinners. In such an example, the motors may be stepper motors or servomotors, so that their rotation can be precisely controlled. Alternatively, or additionally, the axles37,57and/or the motors41,61may include rotary encoders, so that their rotational position can be monitored and controlled by the control system.