Abstract:
A modular fireplace burner assembly replacement method comprises providing a burner assembly positioned on a floor of a fireplace, turning off the gas source, decoupling a gas connection of the burner assembly from the gas source, removing the burner assembly from the fireplace, altering the burner assembly, positioning the burner assembly on floor of the fireplace, coupling the gas connection to the gas source, and turning on the gas source. The step of altering the burner assembly may include repairing the burner assembly or one or more subcomponents thereof, performing maintenance on the burner assembly or one or more subcomponents thereof, cleaning the burner assembly or one or more subcomponents thereof, or replacing the burner assembly or one or more subcomponents thereof.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     The present application is based on and claims the benefit of U.S. Provisional Patent Application No. 60/778,056 filed on Mar. 1, 2006, which the entire contents of which is hereby expressly incorporated by reference. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     The present invention is directed to a fireplace, and in particular to a modular fireplace and methods of using the same.  
         [0004]     2. Description of the Related Art  
         [0005]     Fireplaces are often used to heat living spaces. Typically, fireplaces can be either wood-burning or gas-burning. Gas-burning fireplaces are advantageous when compared to wood-burning fireplaces because they provide immediate heating, are convenient to light, and avoid problems associated with purchasing, handling, and storing wood logs. In a gas-burning fireplace, one or more artificial, non-combustible logs that resemble natural logs are often positioned atop a grate that is located on the floor of the fireplace. A burner connected to a gas source is often located beneath the logs. When gas emitted from the burner is ignited, the artificial logs and the resulting flames simulate the appearance of a wood-burning fireplace. The appearance of the artificial log assembly can significantly impact the aesthetic characteristics of the flame produced by the burner and the overall “look” of the fireplace.  
       SUMMARY OF THE INVENTION  
       [0006]     Installation of a gas-burning burner assembly in a fireplace is often too complex for the average homeowner. Installation may require the skill of a professional. Additionally, a person installing a gas-burning burner assembly can encounter additional difficulties because the burner assembly may comprise a variety of separate components that are assembled together. The burner assembly can comprise, for example, a burner for burning gas, a gas connection, a grate, a base, and one or more artificial logs. The artificial logs can form an artificial log assembly that resembles a stack of wood logs. In some embodiments, the logs are coupled together to form a unitary structure.  
         [0007]     The difficulties posed by installation of a gas-burning burner assembly can significantly diminish a user&#39;s ability to alter the aesthetic characteristics of the fireplace by replacing the artificial log assembly. Also, similar difficulties are encountered when attempting to alter a component of the fireplace, such as the burner assembly, for purposes of repair, maintenance, or replacement of a fireplace component. As used herein, the term “repair” is a broad term and includes, without limitation, restore, replace, refurbish, or otherwise improve the performance of the component. Moreover, when the component (e.g., the burner assembly) is removed from the fireplace during one of the aforementioned alterations, the complexity of installation precludes substitution of the burner assembly. In other words, a user of the fireplace will not be able to use the fireplace during the alteration.  
         [0008]     In one embodiment, a modular fireplace burner assembly replacement method comprises providing a burner assembly positioned on a floor of a fireplace. Gas flow from the gas source is stopped. A gas connection of the burner assembly is decoupled from the gas source. The burner assembly is removed from the fireplace. In some variations, the burner assembly is altered by positioning the burner assembly on floor of the fireplace, coupling the gas connection to the gas source, and turning on the gas source. In some variations, the method further comprises repairing the burner assembly or one or more subcomponents thereof, performing maintenance on the burner assembly or one or more subcomponents thereof, cleaning the burner assembly or one or more subcomponents thereof, and/or replacing the burner assembly or one or more subcomponents thereof. As used herein, the term “subcomponents” is a broad term and includes, without limitation, a portion or component of an entire assembly. For example, a subcomponent of the burner assembly can be a burner, log (e.g., an artificial log or wood log), grate, base, etc.  
         [0009]     In another embodiment, a modular fireplace burner assembly replacement method comprises providing a first burner assembly positioned on a floor of a fireplace. A gas connection of the first burner assembly is decoupled from a gas source. The first burner assembly is removed from the fireplace.  
         [0010]     In another embodiment, a modular fireplace includes a first burner assembly positioned on a floor of a fireplace. The first burner assembly is removed from the fireplace. A second burner assembly is then placed the fireplace. In some variations, the first burner assembly is visually distinct from the second burner assembly.  
         [0011]     In yet another embodiment, a method of altering a modular fireplace comprises removing a first burner assembly from the fireplace. The first burner assembly is configured to burn fuel when installed in the fireplace. After removing the first burner, second burner assembly is installed in the fireplace. Maintenance is performed on the first burner assembly. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]      FIG. 1  is a front view of a fireplace with a burner assembly installed and coupled to a gas source.  
         [0013]      FIG. 2A  is a front view of a portion of the fireplace of  FIG. 1 .  
         [0014]      FIG. 2B  is a front view of the fireplace of  FIG. 2A  after the burner assembly has been removed from the fireplace.  
         [0015]      FIG. 3  is a perspective view of the burner assembly as a log assembly is being removed from a grating.  
         [0016]      FIG. 4A  is a front view of the burner assembly after the log assembly has been removed.  
         [0017]      FIG. 4B  is a perspective view of the burner assembly with some of the log assembly in place.  
         [0018]      FIG. 4C  is a perspective view of the burner assembly with some of the log assembly in place.  
         [0019]      FIG. 4D  is a perspective view of the burner assembly with a fully assembled log assembly in place.  
         [0020]      FIG. 5  is a perspective view of the fireplace as the burner assembly is being positioned inside the fireplace.  
         [0021]      FIG. 6  is a perspective view of the fireplace after the burner assembly has been placed inside the fireplace.  
         [0022]      FIG. 7A  shows a part of a gas connection that can be connected to the gas source.  
         [0023]      FIG. 7B  shows a part of the gas connection that can be connected to the burner of the burner assembly. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0024]      FIG. 1  illustrates a modular fireplace assembly that can be used to burn fuel. The illustrated installed fireplace assembly  100  includes a removable burner assembly  110 . The fireplace assembly  100  can be used in various settings, such as in residential dwellings, hotels, commercial settings, indoors, outdoors, and the like. Fuel (e.g., gas such as natural gas, wood, pellets, etc.) can be burned in the fireplace assembly  100 . The illustrated fireplace assembly  100  is a gas-burning fireplace dimensioned for use in a residence, and the burner assembly  110  comprises a pile of logs. The burner assembly  110  can be removed from the fireplace assembly  100  to, e.g., alter the appearance of the fireplace, replace or repair the burner assembly, perform maintenance, and the like.  
         [0025]     The burner assembly  110  is positioned on the floor of the fireplace  105  and is in communication with a gas connection  120 , which is coupled to a gas source  115 . In some embodiments, other types of fuel sources and delivery constructions can be used. Gas from the fuel source  115  can flow through the gas connection  120  to the burner assembly  110  for combustion.  
         [0026]     As noted above, the burner assembly  110  can be removed from the fireplace assembly  100  to perform repairs, maintenance, or can be replaced with another burner assembly  110  as noted above. To alter the overall appearance of the fireplace assembly  100 , the illustrated burner assembly  110  can be replaced with another burner assembly that is visually distinct from the illustrated burner assembly  110 .  
         [0027]      FIG. 2A  shows the burner assembly  110  immediately prior to removal from the fireplace  100 . The burner assembly  110  is positioned on the floor of the fireplace  105 . Prior to removal of the burner assembly  110 , the gas source  115  can be turned off. The gas connection  120  of the burner assembly  110  can then be decoupled from the gas source  115 . The burner assembly  110  can be removed from the fireplace assembly  100 , as shown in  FIG. 2B . A base or bottom plate  113  can be attached to the burner assembly  110 . As such, the bottom plate  113  and burner assembly  110  can be removed together. In some embodiments, the base or bottom plate  113  can be provided separate from the burner assembly and/or can be separately mounted. The bottom plate  113  can have connectors, fittings, or other structures for mating with gas lines or connectors of the fireplace. Another burner assembly can then be installed into the empty fireplace. The installed burner assembly can be visually distinct from the burner assembly  110 . Accordingly, the aesthetics of the fireplace assembly  100  can be altered as desired.  
         [0028]      FIG. 2B  shows the burner assembly  110  after it has been removed from the floor of the fireplace  105 . In some embodiments, the bottom plate  113  of the fireplace  100  can remain in the fireplace  100  when the burner assembly  110  is removed. After the illustrated gas source  115  has been turned off and decoupled from the gas connection  120 , the burner assembly can be removed from the fireplace  100 . If maintenance needs to be preformed on the burner assembly  110  (e.g., if the burner assembly is malfunctioning) the assembly  110  can be removed for an extended period of time, such as one day, two days, four days, a week, multiple weeks, or one or more months. Another burner assembly  110  can be installed in the fireplace  100  so that the fireplace can be utilized even though the original burner assembly  110  has been removed.  
         [0029]     In some embodiments, including the illustrated embodiment of  FIG. 3 , the burner assembly  110  comprises a burner  135 , a holder or grate  130 , a gas connection  120 , and a decorative element  125 . The decorative element  125  can be an artificial log assembly that preferably resembles natural logs. The logs can resemble different types of wood, such as birch, pine, oak, walnut, driftwood, and the like. However, the decorative element  125  can have other designs and configurations that can be positioned upon the grate  130  and burner  135 , which can discharge fuel that is burned. The burner assembly  110  can comprise various types of fittings, connectors, valves, and piping. The size and configuration can be selected based on the configuration of the gas feed system of the fireplace.  
         [0030]     The illustrated burner  135  of  FIG. 3  is configured to output fuel in the form of gas. An elongated conduit  136  extends along an elliptical path and has a plurality of apertures  137  along its length. The illustrated elongated conduit  136  has a somewhat circular axial cross-section; however, the burner  135  can have other cross-sectional shapes and configurations.  
         [0031]     Additionally or alternatively, the burner assembly  110  can comprise a base  140 . The base  140  can have different types of designs and configurations. For example, the base  140  of  FIG. 2B  is a plate having a pattern formed by bricks. The base  140  can also have other designs. In some other embodiments, the base  140  contains an insulating material  145  that can reduce or inhibit heat transfer through the base  140 . In some embodiments, the entire burner assembly  110  can be removed by lifting the base  140  from the floor of the fireplace  105 , as shown in  FIG. 2B .  
         [0032]     A burner mounting structure  141  preferably couples the burner  135  to the base  140  and forms at least a portion of the grate  130 . The burner mounting structure  141  and the grate  130  cooperate to hold the decorative element  125  resting thereon. The design and configuration of the mounting structures  141  can be selected based on the configuration of the burner  135 .  
         [0033]     In some embodiments, the illustrated decorative element  125  can be replaced with a second log assembly (or other decorative element) so as to alter the overall aesthetic of the fireplace, as mentioned above. Substituting one decorative element for another not only alters the visual appearance of the fireplace or burner assembly  110  but may also alter the visual appearance of the flames generated by the burner assembly  110 . Additionally or alternatively, the decorative element  125 , gas connection  120 , and/or burner  135  can be removed and replaced with different components. In some embodiments, for example, these components are removed so that the fireplace can be used as a wood burning fireplace. Natural wood logs can be placed on the grate  130  positioned on the floor of the fireplace  105 . Doing so can increase the versatility of the fireplace  100 , permitting it to be both gas-burning and wood-burning.  
         [0034]     One or more components of the burner assembly  110  may be repaired or replaced. In some embodiments, a first burner assembly  110  can be removed and replaced with another burner assembly. The first burner assembly  110  can be repaired at a different location, preferably off-site. The fireplace  100  can thus be used while maintenance is being performed on the first burner assembly  110 .  
         [0035]      FIG. 4A  illustrates the grate  130  after the decorative element  125  and burner  135  have been removed. The grate  130  is positioned above the bottom plate  113 , which preferably contains an insulative material  145 . The insulative material  145  can be comprised of one or more heat resistant materials. The insulative material  145  can be vermiculite, a member of the phyllosilicate group of materials, or other insulating material. The insulative material  145  serves to insulate the bottom plate  113  of the burner assembly  110 , the base  140  of the burner assembly  110 , and the floor of the fireplace  105  from the heat generated by the burning fuel. In one embodiment, the bottom plate  113  does not comprise insulating material. For example, the bottom plate  113  can be a metal plate without an insulating layer.  
         [0036]      FIGS. 4B-4D  illustrate one method of assembling the decorative element  125 . A first log  151  is placed upon the grate  130 . A second log  152  is then placed upon the grate  130 , followed by a third log  153 . A fourth  154  and fifth log  155  subsequently are placed on top of the other logs, as shown in  FIG. 4C . After logs  151 ,  152 ,  153 ,  154 ,  155  have been placed on top of the grate  130 , the burner assembly  110  is ready to be positioned on the floor of the fireplace  105 . The decorative element  125  can have any number of logs. Moreover, the placement of the logs can be altered to change the appearance of the decorative element  125 .  
         [0037]      FIG. 5  illustrates the partially assembled burner assembly  110  being positioned onto the floor of the fireplace  105 , and  FIG. 6  shows the fireplace  100  after the fully assembled burner assembly  110  has been positioned on the floor of the fireplace  105 . Once the burner assembly  110  is positioned on the floor of the fireplace  105 , the gas connection  120  of the burner assembly  110  is coupled to the gas source  115 . The gas source  115  is then turned ON to permit gas from the gas source  115  to travel to the burner  135  of the burner assembly  110  via the gas connection  120 . The gas connection  120  can comprise any number of gas conduits, regulators, valves (e.g., globe valves, check valves, etc.), and connectors.  
         [0038]      FIGS. 7A and 7B  illustrate the gas connection  120  configured to provide fluid communication between the gas source  115  and the burner  135 .  FIG. 7A  shows the portion of the gas connection  120  coupled to the gas source  115 , and  FIG. 7B  shows the portion of the gas connection  120  coupled to a regulator  122 . In some embodiments, the regulator  122  permits a user to control the flow of gas to the burner  135 .  
         [0039]     The embodiments, features, systems, devices, materials, methods and techniques described herein may, in some embodiments, be similar to any one or more of the embodiments, features, systems, devices, materials, methods and techniques described in U.S. application Ser. No. 10/793,325, filed on Mar. 4, 2004, which incorporated by reference in its entirety. In addition, the embodiments, features, systems, devices, materials, methods and techniques described herein may, in certain embodiments, be applied to or used in connection with any one or more of the embodiments, features, systems, devices, materials, methods and techniques disclosed in the above-mentioned U.S. application Ser. No. 10/793,325. For example, the fireplace  100  described above can have prefabricated brick panels.  
         [0040]     The articles disclosed herein may be formed through any suitable means. The various methods and techniques described above provide a number of ways to carry out the invention. Of course, it is to be understood that not necessarily all objectives or advantages described may be achieved in accordance with any particular embodiment described herein. Thus, for example, those skilled in the art will recognize that the methods may be performed in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objectives or advantages as may be taught or suggested herein.  
         [0041]     Furthermore, the skilled artisan will recognize the interchangeability of various features from different embodiments disclosed herein. Similarly, the various features and steps discussed above, as well as other known equivalents for each such feature or step, can be mixed and matched by one of ordinary skill in this art to perform methods in accordance with principles described herein. Additionally, the methods which are described and illustrated herein are not limited to the exact sequence of acts described, nor are they necessarily limited to the practice of all of the acts set forth. Other sequences of events or acts, or less than all of the events, or simultaneous occurrence of the events, may be utilized in practicing the embodiments of the invention.  
         [0042]     Although the invention has been disclosed in the context of certain embodiments and examples, it will be understood by those skilled in the art that the invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses and obvious modifications and equivalents thereof. Accordingly, it is not intended that the invention be limited, except as by the appended claims.