Abstract:
A three-dimensional panel used in an electric fireplace to simulate a firebox of a wood burning fireplace and an electric fireplace incorporating the same. The electric fireplace includes housing having a light source positioned so as to transmit light through the panel. The panel is vacuum-molded to have a pattern formed therein and thereon. The pattern represents elements found in a wood burning fireplace such as firebricks, stoneworks, logs, a logset, a grate and embers or any other elements typically found in a wood-burning fireplace&#39;s firebox. The pattern is formed by a combination of molding these elements into the materials from which the panel is made and applying coloring agents to the panel either during the molding process or after the panel has been formed. The panel may be positioned between an artificial logset and the light source if the logset is not molded into the panel.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a Continuation-In-Part of U.S. patent application Ser. No. 11/699,727, filed Jan. 30, 2007, the entire specification of which is incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Technical Field 
         [0003]    This invention generally relates to fireplaces. More particularly, the invention relates to electric fireplaces which simulate the appearance of a wood-burning or gas-burning fireplace. Specifically, the invention relates to a three-dimensional panel having a pattern of elements of a firebox molded and colored thereon, where the panel is positionable in front of a light source in an electric fireplace to simulate a wood-burning fireplace. 
         [0004]    2. Background Information 
         [0005]    Fireplaces may add to the warmth and ambiance of any room. However, in many locations, installing a wood-burning or gas-burning fireplace is not practical or even possible because of space constraints or venting issues. In warmer climates, on the other hand, homeowners may want the ambiance offered by a fireplace but do not want any heat to be emitted therefrom. It is in these instances that electric fireplaces are the ideal solution. 
         [0006]    An electric fireplace will only tend to add to the appearance of a room if it creates an effective illusion that it is a wood-burning or gas-burning fireplace. This has caused manufacturers to include various components in electric fireplaces that are essentially decorative and not functional. So, for example, electric fireplaces include a grate, artificial firelogs and embers, and none of these components contribute to the production of heat from the fireplace. Furthermore, the fireplaces have included mechanisms for creating the illusion of burning firelogs. These mechanisms have included providing a rotating cylinder that has flame-shaped apertures formed in its exterior surface. A light is shone through the rotating cylinder and onto a diffuser screen positioned behind the firelogs. Other fireplaces, such as those disclosed in U.S. Pat. Nos. 6,393,207 and 6,757,487 both issued to Martin et al, include a screen on which colored flame-shaped images are silk-screened. A light is shone through an apertured rotating cylinder positioned rearwardly of the screen and the moving light causes the silk-screened images to appear to flicker, thereby creating the illusion of burning logs 
         [0007]    Another of the components that manufacturers have needed to include, but which does not serve any functional purpose, is a firebox in which the grate, artificial firelogs and embers are presented. So, for example in the patents to Martin et al referenced previously, a simulated firebox insert having a top, a bottom, a back and sides, is positioned within a cavity in a housing. The sides of the insert are painted to appear like firebricks or, alternatively, ceramic fiber refractory panels which are appropriately shaped and colored are attached to the interior sides of the insert. These additional components add to the cost of manufacturing the electric fireplace. 
         [0008]    There is therefore a need in the art for an improved electric fireplace that has the illusion of a firebox for a wood-burning or gas-burning fireplace, but that does not require the actual construction of a firebox during manufacture of the unit. 
       SUMMARY OF THE INVENTION 
       [0009]    The device of the present invention comprises a three-dimensional panel used in an electric fireplace to simulate a firebox of a wood burning fireplace and an electric fireplace incorporating the same. The electric fireplace includes housing having a light source positioned so as to transmit light through the panel. The panel is vacuum-molded to have a pattern formed therein and thereon. The pattern represents elements found in a wood burning fireplace such as firebricks, stoneworks, logs, a logset, a grate and embers or any other elements typically found in a wood-burning fireplace&#39;s firebox. The pattern is formed by a combination of molding these elements into the materials from which the panel is made and applying coloring agents to the panel either during the molding process or after the panel has been formed. The panel may be positioned between an artificial logset and the light source if the logset is not molded into the panel. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    The preferred embodiments of the invention, illustrative of the best mode in which applicant has contemplated applying the principles, are set forth in the following description and are shown in the drawings and are particularly and distinctly pointed out and set forth in the appended claims. 
           [0011]      FIG. 1  is a front elevational view of an electric fireplace in accordance with the present invention; 
           [0012]      FIG. 2  is a cross-sectional side view of the electric fireplace taken through line  2 - 2  of  FIG. 1 ; 
           [0013]      FIG. 3  is a front view of a first embodiment of a panel for use in the electric fireplace of  FIG. 1 ; 
           [0014]      FIG. 4  is a front view of a second embodiment of a panel for use in the electric fireplace; 
           [0015]      FIG. 5  is a front view of a third embodiment of a panel for use in the electric fireplace; 
           [0016]      FIG. 6  is a side view of a fourth embodiment of a panel for use in the electric fireplace; 
           [0017]      FIG. 7  is a front elevational view of an alternative embodiment of a fireplace in accordance with the present invention; 
           [0018]      FIG. 8  is a cross-sectional side view of the electric fireplace of  FIG. 7 . 
           [0019]      FIG. 9  is a front elevational view of a further alternative embodiment of a fireplace in accordance with the present invention; 
           [0020]      FIG. 10  is a cross-sectional side view of the electric fireplace taken through line  10 - 10  of  FIG. 9 ; 
           [0021]      FIG. 11  is a front elevational view of a first embodiment of the three-dimensional panel in accordance with the present invention; 
           [0022]      FIG. 12  is a rear perspective view of the panel of  FIG. 11 ; 
           [0023]      FIG. 13  is an enlarged rear perspective view of the highlighted region of  FIG. 12 ; 
           [0024]      FIG. 14  is a side view of the panel taken through line  14 - 14  of  FIG. 13 ; 
           [0025]      FIG. 15  is front elevational view of a second embodiment of the three-dimensional panel in accordance with the present invention; and 
           [0026]      FIG. 16  is a rear perspective view of the panel of  FIG. 15 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0027]    Referring to  FIGS. 1-6 , there is shown an electric fireplace  10  in accordance with the present invention. Fireplace  10  comprises a housing that includes a mantel  12 , a base  14  and side panels  16 ,  18  that surround and define an interior cavity  20 . Fireplace  10  has the appearance of being a natural wood-burning fireplace when viewed from a front end  10   a  thereof and includes a grate  22 , artificial firelogs  24  and an ember bed  26  which are positioned within cavity  20 . A light source (not shown) may be provided in base  14  to illuminate ember bed  26  from beneath, as is known in the art. 
         [0028]    One or more rotatable cylinders  28 ,  30  may be positioned rearwardly of firelogs  24 . Cylinders  28 ,  30  each have an outer surface in which a plurality of flame-shaped apertures (not shown) are formed. Light from a light source  29  shines through the outer surface of cylinders  28 ,  30  and through these flame-shaped apertures. As the cylinders  28 ,  30  rotate, the light shining through the apertures is directed forwardly toward front end  10   a  of fireplace  10  and onto a diffuser screen  32 . An image of a plurality of flames  36  is thereby formed on diffuser screen  32  by the light. 
         [0029]    In accordance with a specific feature of the present invention, fireplace  10  is provided with a panel  34  situated between diffuser screen  32  and cylinders  28 ,  30 . Panel  34  preferably is a planar sheet that is at least partially one of opaque, translucent or transparent to allow some light to be transmitted therethrough. Panel  34  is provided with a pattern thereon to represent the interior of a firebox of a wood-burning fireplace. In the preferred embodiment of the invention, pattern  38  is one of a plurality of firebricks. This is illustrated in a first embodiment in  FIG. 3  where the panel shows a flat wall of firebricks. In a second embodiment shown in  FIG. 4 , the panel shows a recessed wall of firebricks. It will be understood, however, that any other suitable pattern may be utilized on panel  34 , such as one to simulate the stonework of a firebox in a stone fireplace. Furthermore, the pattern  38  may also include a three-dimensionally recessed or protruding logset  39  which includes a plurality of logs seated on a grate above an ember bed. This third embodiment is shown in  FIG. 5 . 
         [0030]    It will also be understood that the pattern  38  preferably is produced at least partially in color. The pattern  38  is formed on panel  34  any suitable method including silk screening, painting, etching or any combination of these. 
         [0031]    While panel  34  has been disclosed above to preferably be a planar sheet, it will be understood that panel  34  may also be integrally formed with or otherwise attached to the logset without departing from the spirit of the present invention. This fourth embodiment is shown in  FIG. 6  where the panel  32  is attached by an adhesive  23  to one or more of the grate  22 , logs  24  and ember bed  26 . 
         [0032]    Fireplace  10  is used in the following manner. A switch (not shown) is used to activate both the light source  29  and cylinders  28 ,  30 . As cylinders  28 ,  30  are rotated, the light from light source  29  passes through the flame-shaped apertures in the rotating cylinders  28 ,  30 , through panel  34  and through diffuser screen  32 . The pattern of firebricks  38  on panel  34  is illuminated by the light forming the flame-shaped images  36  on diffuser screen  32 . This creates the illusion, when viewed from the front end  10   a  of fireplace  10 , that the firelogs  24  are burning and that the flames are illuminating a portion of the firebox in which the logs are situated. The illusion of a firebox is thus created by the provision of the planar panel  34 . There is therefore no need for the construction of a specially shaped firebox to be received within a cavity of the fireplace housing. The panel  34  is simply positioned across a rear portion of the generally rectangular cavity  20  formed by the mantel, base and sides. There is also no need for painting a brickwork pattern onto the interior side walls of a specially shaped firebox or for the attachment of ceramic fiber panels onto the interior side walls thereof. Panel  34  therefore reduces the time required and the cost for manufacturing an electric fireplace. 
         [0033]    Referring to  FIGS. 7 and 8 , there is shown an alternative embodiment of a fireplace in accordance with the present invention and generally indicated at  110 . Fireplace  110  includes a housing having a mantel  112 , a base  114  and side panels  116 ,  18  that surround and define an interior cavity  120 . Fireplace  110  includes a grate  122 , artificial firelogs  124 , and ember bed  126  positioned within the cavity  120 . As with the previous embodiment, a light source  129  is provided to shine through flame-shaped apertures in cylinders  128 ,  130 . In this instance, fireplace  10  includes a single diffuser panel  140  positioned intermediate firelogs  124  and cylinders  128 ,  130 . Panel  140  is a planar sheet that is at least partially one of opaque, translucent and transparent and is provided with a pattern  138  of firebricks thereon. Pattern  138  is formed by silk-screening, painting or etching firebricks onto the diffuser panel  140 . When diffuser panel  140  is illuminated with the flame pattern produced by light shining through the flame-shaped apertures in cylinders  128 ,  130 , panel  140  creates the illusion that fireplace  110  includes a firebox in which the firelogs  124  are burning. The pattern  138  on diffuser panel  140  may be of any suitable type such as that illustrated in  FIG. 7 . It will be understood, however, that any other suitable pattern may be utilized on panel  140 , such as one to simulate a flat brick wall or a firebox of a stone fireplace, for example. 
         [0034]    It will be understood that the illusion of the flames may be created in a manner other than by shining light through flame-shaped apertures in one or more rotating cylinders, without departing from the spirit of the present invention. So, for example, light from the light source may shine directly on the panel or the fireplace may include a screen in which the flames are preformed such as by silk-screening or painting. Furthermore, the pattern  38 ,  138  of the firebricks disclosed and claimed herein may be superimposed upon any such screen. 
         [0035]    Referring to  FIGS. 9-14  there is shown an further embodiment of an electric fireplace in accordance with the present invention and being generally indicated at  210 . Fireplace  210  comprises a housing that includes a mantel  212 , a base  214  and side panels  216 ,  218  that surround and define an interior cavity  220 . Fireplace  210  has the appearance of being a natural wood-burning fireplace when viewed from a front end  210   a  thereof. A light source (not shown) may be provided in base  214  to illuminate panel  234  from beneath. 
         [0036]    One or more rotatable cylinders  228 ,  230  may be provided in fireplace  210 . If provided, cylinders  228 ,  230  may each have an outer surface in which a plurality of apertures (not shown) are formed. Light from a light source  229  shines through the outer surface of cylinders  228 ,  230  and through these apertures. As the cylinders  228 ,  230  rotate, the light shining through the apertures is directed forwardly toward front end  210   a  of fireplace  210 . The apertures may be flame shaped or shaped in any other desired pattern. Alternatively, as mentioned previously, cylinders  228 ,  230  do not need to be provided in order to generate the flickering flame images. Instead, light from light source  229  may shine directly onto panel and the relief or profile created in the panel itself may create the flickering flame illusion in the panel. 
         [0037]    In accordance with a specific feature of the present invention, fireplace  210  is provided with a three-dimensional molded panel  234  that is positioned in front of cylinders  228 ,  230 . Panel  234  preferably is a unitary member that is molded from PETG (glycol-modified polyethylene terephthalate). It will be understood that other types of vacuum formable or castable plastics may be used with the castable plastics being brushed, poured or injected. The PETG preferably is between 0.009″ and 0.063″ thick, although greater thicknesses of the plastic, such as around 0.125″ thick could be used when spanning larger distances to prevent bowing of panel  234 . Thinner plastic may also be utilized. Panel  234  is manufactured in such a way as to be transparent, opaque or translucent so that light may travel therethrough. 
         [0038]    Panel  234  includes a top wall  260 , a bottom wall  262 , side walls  264 ,  266  and a back wall  268 , all of which are preferably integrally connected to each other. The top, bottom, side and back walls could, however, be separately formed and joined together in a suitable manner. Top, bottom, side and back walls are positioned at angles relative to each other with the angle being established by the desired finished appearance of panel  234  and the amount of perspective that it is desired that the panel should have. Bottom wall  262  constitutes a base from which top, sides and bottom walls  260 ,  264 ,  266  and  262  extend outwardly and forwardly. Top wall  262  extends outwardly and slightly upwardly away from a top end  268   a  ( FIG. 10 ) of back wall  268 . Bottom wall  262  extends outwardly and slightly downwardly from a bottom end  268   b  of back wall  268 . Preferably, top wall  260  and bottom wall  262  are at an angle α of between 0 degrees and 90 degrees relative to the planar vertical surface of back wall  268  and preferably between 30 degrees and 90 degrees, although any other suitable angle may be selected. To date, panels  234  have been produced with angle α being set at 44 degrees, 51 degrees, 61 degrees and 77 degrees. Side wall  264  extends outwardly from a first side  268   c  ( FIG. 11 ) of back wall  268 . Side wall  266  extends outwardly from a second side  268   d  of back wall  268 . Preferably, side walls  264 ,  268  are at an angle β relative to the planar surface of back wall  268  and therefore flare outwardly away from back wall  268 . It has been found that angle β preferably is similar to angle α, and finished panels have been produced with angle β being set at between 40 degrees and 60 degrees. Each side wall  264 ,  268  is also integrally connected between a portion of top wall  260  and a portion of bottom wall  262 . A flange  270  frames the front edges of top, bottom and side walls  260 ,  262 ,  264  and  266  and creates a lip  270   a  ( FIG. 12 ) that radiates outwardly away from the outer surfaces of these walls. When panel  234  is placed in fireplace  210 , the lip  270   a  of flange  270  butts up against an interior surface  272  of the frame formed by the mantel  212 , base  214  and sides  216 ,  218  of fireplace  210 . Flange  270  therefore is substantially hidden when fireplace  210  is viewed from the front as in  FIG. 9 . An adhesive or other suitable securement may be applied between flange  270  and the frame of fireplace  210 . 
         [0039]    As shown in  FIG. 12 , a lowermost portion of back wall  268  and portion of bottom wall  262  may be molded into the shape of a logset  274  and embers  276 . Logset  274  and embers  276  project forwardly and outwardly in front of the upper portion of back wall  268  and project upwardly from bottom wall  262 . Furthermore, as shown in  FIGS. 13 and 14 , back wall  268  and side walls  264 ,  266  of panel  210  are molded into the shape of bricks  278  that are separated by channels of grout  280 . The molded panel  210  may also be formed to include smaller protrusions and recesses (not shown) in the individual bricks  278  so that the walls of panel  210  have a more realistic and textured appearance. Preferably, the transitions between the back wall  268  and the top, bottom and side walls  260 ,  262 ,  264  and  266  are somewhat hidden by molding of grout lines  280  in those transition locations. This is indicated in  FIG. 11  by lines  280   a.    
         [0040]    Paints, dyes or any other suitable coloring agents  282  may be applied over either of the front or rear surfaces of any or all of the walls of panel  234 . This is illustrated in  FIG. 14  where coloring agents  282  are applied over front surface  268   e  of back wall  268 . Back surface  268   f  thereof is free of coloring agents. It will be understood that coloring agents could, however, also be applied over back surface  268   f . Furthermore, the coloring agents may be applied in various regions of panel  234  to different degrees. In some regions of panel  234  the coloring agents may be applied in such a manner that light from light sources  229  passes easily through the coloring agent and is therefore visible from the front of fireplace  210 . In other regions of panel  234 , the coloring agents may be applied to a degree sufficient to substantially prevent light from being transmitted through those particular regions. So, for example, a quantity of the coloring agents may be applied to darken a large portion of the logs in the logset  274  thereby causing the logs to appear as substantially solid bodies. This occurs because the thickness and coloration of these regions substantially restrict light from light sources  229  from traveling therethrough. Alternatively, at least a portion of the coloring agents may be added into the material to be molded so that the molded panel  234  is at least partially colored during the molding process. Additional coloring agents may also be applied over this molded and colored panel. It will be understood that any of the top, bottom, side and back walls  260 ,  262 ,  264 ,  266  and  268  may be molded and colored to represent features typically found in a wood fireplace, including but not limited to bricks, stones, logs, embers, a grate and flames. Furthermore, at least one of the walls, such as top wall  260  may be molded so as to be free of texture, i.e., not including any bricks or stones or other fireplace features. This wall or other walls may also be devoid of any coloring agents if desired. 
         [0041]    In use, panel  234  is placed in the frame formed by mantel  212 , base  214  and sides  216 ,  218  so that flange  270  butts up against the interior walls of the fireplace frame and is not visible when fireplace  210  is observed from the front. Panel  234  is positioned within this frame so that the light sources  229  in cylinders  228 ,  230  will shine through back wall  268  and possibly through a portion of bottom wall  262  and side walls  264 ,  266  and give the appearance of flames  284  ( FIG. 9 ) flickering in fireplace  210 . An additional light source (not shown) may also be positioned beneath bottom wall  262  so that the embers  276  molded into the same will appear to flicker and glow. Fireplace  210  may also be provided with a noise generator (not shown) that emits sounds which simulate crackling wood, thereby enhancing the illusion that this electric device is in fact a wood burning fireplace. 
         [0042]    Referring to  FIGS. 15 and 16 , there is shown a second embodiment of a three dimensional molded panel for use in an electric fireplace and generally indicated at  334 . Panel  334  is substantially identical to panel  234 , having a top wall  360 , bottom wall  362 , side walls  364 ,  366  and a back wall  368 . Panel  334  is manufactured in substantially the same manner as panel  234 . In this second embodiment, however, back wall  368  does not incorporate a logset design and is generally planar in nature. Back wall  368  is molded to simulate other fireplace features such as the firebricks  378  and grout  380  shown in  FIG. 16 . It could, of course, be molded to represent stones or other similar features. Furthermore, bottom wall  360  is shown in  FIG. 16  to be molded to include embers  376 . Bottom wall  360  may, alternatively, be molded as a planar member and the embers may be painted onto the same. Alternatively, bottom wall  360  may simply be colored in a darker background color. When panel  334  is positioned within a fireplace frame in a like manner to the previous embodiment, a separate logset (not shown) with or without a grate and an ember bed may be positioned in front of the back wall  368 . This separate logset may rest partially or entirely on bottom wall  362  and may be secured to one or both of bottom and back walls  362 ,  368  by a suitable means such as an adhesive or fasteners. 
         [0043]    It will be understood that either embodiment of the three-dimensional panel may be used in conjunction with a diffuser screen (not shown) separating the panel from the light sources within the rotating cylinders, although the intent is that the panel act as the diffuser screen for the fireplace. 
         [0044]    In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed. 
         [0045]    Moreover, the description and illustration of the invention are an example and the invention is not limited to the exact details shown or described.