Flame simulating assembly with occluded shadow imaging wall

A flame simulating assembly for providing a moving effect of flames. The assembly includes a light source; a flicker element disposed in the path of the light source configured and arranged to reflect light from the light source; and an imaging wall. The imaging wall is disposed above the light source and includes a front facet and at least one additional facet. The front facet has an upper portion disposed forward of a lower portion thereof and the at least one additional facet extending rearward from the front facet. Light from the flicker element is occluded by the front facet to provide a more realistic fire shape. The fire shape appears wider at the base than at the top.

BACKGROUND

1. Technical Field

The present patent document relates generally to artificial or simulated fireplaces and stoves, and more particularly to a flame simulating assembly with an occluded shadow imaging wall.

2. Background of the Related Art

In simulated fireplaces, electronic flames, or simulated flames, are often used in a flame simulator to provide the simulated fireplace an optical visual effect and to play a role in decoration. In one type of flame simulator, a light source and rotating reflector is installed behind a slotted flame-shaped wall. As the reflector rotates, light is periodically emitted through the flame-shaped wall and onto a screen, which simulates the flames by providing a flickering effect to the light projected through the slotted wall. The reflector may also be referred to as a flicker element.

The light may optionally be reflected off a mirror and onto the screen. The light may be projected onto the front of the screen or, with a light-transmitting screen, onto the rear of the screen. In either case the screen is flat and, consequently, the simulated flame lacks depth. Furthermore, the brightness of the flame tends to be more uniform, which detracts from the visual appearance.

Therefore, there is a perceived need in the industry for a simulated flame with enhanced depth and brightness that more closely resembles a real flame.

SUMMARY

The present invention solves the problems of the prior art by providing a flame simulating assembly with an occluded shadow imaging wall that is shaped in such a way that light from a flicker element is most intense in the center but fades out towards the corners. The overall shape of the simulated fire is triangular, which more closely simulates a real fire.

DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

Certain exemplary embodiments will now be described to provide an overall understanding of the principles of the structure, function, manufacture, and use of the device and methods disclosed herein. One or more examples of these embodiments are illustrated in the accompanying drawings. Those skilled in the art will understand that the devices and methods specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary embodiments and that the scope of the present invention is defined solely by the claims. The features illustrated or described in connection with one exemplary embodiment may be combined with the features of other embodiments. Such modifications and variations are intended to be included within the scope of the present disclosure. Further, in the present disclosure, like-numbered components of the embodiments generally have similar features, and thus within a particular embodiment each feature of each like-numbered component is not necessarily fully elaborated upon. Additionally, to the extent that linear or circular dimensions are used in the description of the disclosed systems, devices, and methods, such dimensions are not intended to limit the types of shapes that can be used in conjunction with such systems, devices, and methods. A person skilled in the art will recognize that an equivalent to such linear and circular dimensions can easily be determined for any geometric shape. Further, to the extent that directional terms like top, bottom, up, or down are used, they are not intended to limit the systems, devices, and methods disclosed herein. A person skilled in the art will recognize that these terms are merely relative to the system and device being discussed and are not universal.

In an exemplary embodiment, illustrated inFIG. 1, an electric fireplace100can include a housing, or enclosure,101having front and back walls102a,102b, top and bottom walls104a,104b, and side walls106a,106b. Through an opening in the front wall102aa firebox cavity103can be defined which is visible through a transparent glass panel or a set of glass doors (not shown). The firebox cavity103can be defined by a firebox rear wall110, firebox top and bottom walls, and firebox side walls112a,112b. The firebox cavity103can create the appearance of a traditional fireplace firebox. The side walls112a,112band the rear wall110may or may not be given the appearance of brick or stone to provide an authentic look and feel. The side walls112a,112bmay or may not be angled relative to the rear wall110. In some embodiments, a gradation of color from a central location on the firebox rear wall110to the firebox side walls may provide the illusion of soot build-up towards the outer edges while also providing a brighter, lighter central portion for enhanced reflection and flame appearance in the center. For example, a central portion may be yellow, red, brown, or brick colored, and the color can then fade to a black, grey, or generally soot-like color as it extends away from the central portion forming a gradation. Alternatively, the firebox side walls112a,112band the firebox rear wall110can have any appearance, texture, or color.

The interior of the housing can provide space for various internal components of the electric fireplace, including a heater/blower unit (not shown in this embodiment) which provides a warm air flow from the fireplace unit100and further including a flame simulation assembly which provides the visual effect of moving flames on the firebox rear wall110. The flame simulation assembly can include those disclosed in U.S. patent application Ser. No. 16/004,767, filed Jun. 11, 2018, titled “FLAME SIMULATING ASSEMBLY FOR SIMULATED FIREPLACES INCLUDING A REFLECTING LIGHT SYSTEM,” hereby incorporated by reference in its entirety. In an exemplary configuration, the heater is located in a compartment at the top of the housing. However, in alternative embodiments, the heater can be disposed in other areas of the device. In general, the heater/blower unit can be controlled, with a controller (not shown), to provide hot air to heat the surrounding area to further add to the realism of the electric fireplace and its' utility as a space heater. The controller can additionally be used to control the flame simulation assembly and any other feature of the device.

Referring now toFIGS. 2A and 2B, an embodiment of a flame simulating assembly is shown generally in several views. The assembly generally includes an enclosure housing a light source120, a flicker element130, and a unique rear imaging wall110. Light from the light source120can be directed towards the flicker element130. The light can then be reflected upwards and/or rearwards towards a slotted wall, or flame screen150as shown in U.S. application Ser. No. 16/004,767 and onto the imaging wall110thereby simulating the flame. In alternative embodiments, the flame screen can be omitted.

The imaging wall110may be generally rectangular or square in shape, when viewed from the front, with a bottom edge140a, a top edge140b, a left edge142a, and a right edge142bwith corners. In the illustrated embodiment, the top portion144t, proximate the top edge140bprojects forward of the bottom edge140ain the enclosure and is therefore laterally closer to the flicker element130than the bottom edge140a. In some embodiments, the imaging wall110may not occupy the entire rear wall of the firebox103. The most critical portion of the imaging wall is the generally triangular central portion144which acts to image and shape the light forwardly and toward the top into the triangular shape of a fire. In some embodiments, the top portions146b,146c,146dand side portions146aand146emay taper off into the back wall or may be eliminated altogether providing an occluded shadow area. In some embodiments, where the side and/or top portions are eliminated, the terminal edges or seams of the central portion144may include serrated or flame shaped edges.

Referring toFIGS. 2A-2B, an exemplary embodiment is illustrated where the imaging wall has a generally polyhedral shape, with a front facet area144to reflect light and the remaining facets146a-eto form shadows and occlusions to enhance the appearance of a simulated flame. The imaging wall110can be manufactured by any suitable means including blow molding, vacuum molding, injection molding, 3D printing, or may be fabricated from sheet metal pieces, etc. Although the term “facet” is utilized to define the general areas, and linear “seams” are illustrated between the facet areas, it is to be understood that the term is intended to generally describe the shapes and that the “seams” between the facet areas do not need to be sharp angles. The transition from one facet area to another can be smooth and seamless with the same effect.

As illustrated, the front facet144has a general trapezoidal shape, with a top edge144tof the facet144disposed forward of both the bottom and top edges of the wall140a,140b. The top edge144tof the facet144can have a shorter length then the bottom edge of the facet144which can extend the entire length of the bottom edge140bof the imaging wall110. The remaining facets146a-eare angled away from the flicker element and light source, thus eliminating or reducing light reflected onto these other facets. The remaining facets146a-eeach extend from the front facet towards a respective bottom, top, left, or right edge140a,140b,142a,142b. As shown, the remaining facets146a-eare triangular in shape, however other shapes that are angled relative to the front facet144are considered to be within the scope of this disclosure, including square, trapezoidal, etc. In some embodiments, some of the remaining facets146a-ecan each be different shapes or can be the same shapes with different proportions. While five remaining facets146a-eare shown, any number of additional facets can be provided. Due to the remaining facets146a-ebeing angled relative to the front facet144, the light that is reflected from the flicker element130may not, relatively, brightly reflect off of those facets146a-e. As a result of the angle relative to the front facet144, the remaining facets146a-eappear darker and the front facet144appears brighter, thus providing an enhanced triangular shape to the simulated flame. Further, or alternatively, the remaining facets146a-ecan have a non-reflective coating or dark paint to prevent any light from reflecting off the wall. Or as indicated above, the remaining facets may be eliminated.

The imaging wall210may alternatively include a 3-Dimensional (3D) flame shape244molded thereon, as shown inFIGS. 3A and 3B. The flame shape244is generally an impression formed into the front surface of the forwardly angled imaging wall and can be in place of the trapezoidal front facet244and be angled forward from its bottom edge240btowards the front of the fireplace enclosure. The alternative imaging wall210can be manufactured by any suitable means including blow molding, vacuum molding, injection molding, 3D printing, or fashioned from sheet metal pieces, etc. The imaging210wall may further include dark colors formed outside the flame shaped molded section246, thereby providing a shadow boundary that reduces reflection of the simulated flame light. The darker, non-reflective, area246can enhance the shape of the simulated flame to appear more triangular in shape.

Referring toFIGS. 4A and 4B, a further exemplary embodiment of an imaging wall310is shown where a top edge340aof the imaging wall310is bowed outwardly to form a semicircular or arc shape at the top edge and a straight line at the bottom edge340b. The imaging wall310can be formed from a single sheet of material that is bowed outward as described and applied or attached to the rear wall of the fireplace. The alternative imaging wall310can alternatively be manufactured by any suitable means including blow molding, vacuum molding, injection molding, 3D printing, or fashioned from sheet metal or plastic, etc. As a result, a center portion344of the imaging wall310is laterally forward of the bottom edge340b. The left and right corners348a,348bof the top edge340acan be disposed rearward of the center section344. This configuration can provide an imaging surface344on the imaging wall that has a parabolic, triangular, or trapezoidal flame image area. Consequently, the left and right sides346a,346band left and right upper corners348a,348bcan form enhanced occlusions or shadow areas349a,349bthat are blocked from the projected simulated flame which can thus enhance the realism of the flame. In some embodiments, the imaging wall310may not occupy the entire rear portion of the firebox103. The imaging wall may be prominent in the center portion or area and then be truncated or eliminated toward the outer edges. In some embodiments, the imaging wall310may be fashioned from a transparent, coated or partially reflective plastic material and the flat inner surface of the rear wall360is provided with a brick pattern. In this manner, light is reflected from the curved forward imaging surface340, while the brick pattern still appears flat on the back surface360.

Although the embodiments are shown with a reflection system, it would be appreciated by one skilled in the art that the simulated flame assembly described herein may be adapted for a rear projection configuration, or an indirect reflection using one or more mirrors or screens.

Therefore, it can be seen that the simulated flame assembly provides a unique solution to the problems of the prior art by providing a simulated flame assembly with an occluded shadow imaging wall with enhanced depth and brightness that more closely resembles a real flame.

It would be appreciated by those skilled in the art that various changes and modifications can be made to the illustrated embodiments without departing from the spirit of the present invention. All such modifications and changes are intended to be within the scope of the present invention.