Abstract:
A factory-build masonry fireplace includes a firebox, casing, and chimney system, where the firebox defines a cavity. Masonry panels are removably attached to the periphery of the cavity. Each masonry panel has firebrick housings configured to hold a corresponding firebrick, wherein the housings can optionally be arranged in a running bond and herringbone patterns, among others. Additionally, the base masonry panel defines an opening configured to hold a removable ash dump, the opening covered with a removable cover. In another arrangement, masonry panels have protruding walls that are configured to hold a corresponding firebrick. The masonry panels are used to build traditionally site built masonry structures.

Description:
RELATED APPLICATIONS  
       [0001]    This application relates to and claims the benefit of the provisional application 60/452,478, filed Mar. 5, 2003, which is hereby incorporated by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]    1. Field of the Invention 
         [0003]    The present invention is directed to masonry, and in particular to factory built masonry. 
         [0004]    2. Description of the Related Art 
         [0005]    Masonry structures have are well known in the art and have existed for many years. Many traditionally site built masonry structures (e.g., fireplaces, countertops, brick walls, and the like) may have to be constructed by a mason and thus can be expensive. Traditional site built masonry structures can also require significant installation time. For example, site built masonry fireplaces commonly found in residential structures and can be expensive and require substantial installation time. 
         [0006]    Over the years, factory built fireplaces have grown in popularity due to the increased cost of site constructed masonry structures. Additionally, building code restrictions in some localities limit or altogether prohibit the use of masonry chimneys, making the use of factory built fireplaces desirable in these localities. Moreover, factory built fireplaces are capable of being installed in multi-level buildings, where construction of traditional masonry units is not feasible. 
         [0007]    Even where the construction of masonry fireplaces is feasible, construction usually requires a significant amount of time and costs, significantly more than a factory-built fireplace. Additionally, installation of tradition masonry fireplaces generally requires the services of a licensed mason or other construction professional, adding to the cost of construction. 
         [0008]    Throughout the development of the factory-built fireplace industry, designers have sought to design fireplaces to resemble traditional masonry built fireplaces. For example, recent designs of factory-built fireplaces have incorporated refractory panels to better resemble a masonry fireplace. However, such refractory panels, and other similar designs, have been incapable of achieving the desired masonry look. In another example, bricks have been added to the firebox area of a fireplace in an attempt to create a masonry look. However, such construction design has proved structurally unstable, often falling and breaking, and thus unable to provide adequate retention of bricks. Additionally, such designs have provided poor alignment of bricks and have not been capable of providing multiple brick pattern arrangements. 
         [0009]    The desire for factory-built fireplaces that resemble masonry fireplaces is particularly strong among owners and builders of high-end homes, who prefer the traditional look of masonry fireplaces. However, as noted above, some localities restrict or prohibit the use of masonry fireplaces due to, for example, the risk of seismic activity in the locality. Thus, there is a need for factory built masonry structures that resemble site built masonry. 
       SUMMARY OF THE INVENTION  
       [0010]    In accordance with one embodiment of the invention disclosed herein, panels can comprise a backing and a plurality of walls attached to the backing. The walls can have holding members configured to hold a body, such as a brick or tile. The holding members of the walls cooperate to receive and hold firebricks. The holding members can be tabs that extend from the walls of the panels. The walls having the holding members can be generally perpendicular to the panels. The panels can be prefabricated panels used to build traditionally site built masonry structures. The site built masonry structures can be, e.g., fireplaces, countertops, brick walls, or hearths. 
         [0011]    In accordance with one embodiment of the invention disclosed herein, a factory-built fireplace is designed to look like a traditional masonry fireplace. The fireplace comprises a firebox having an inner cavity and a chimney system. The cavity preferably comprises a frame comprising rails or panels that define the periphery of the cavity. The frame defines side areas, a rear area, a base area and a top opening in the firebox, wherein the opening is preferably connected to the chimney system. In addition, the fireplace includes masonry panels configured to be installed on the side areas, rear area and base area of the cavity frame. 
         [0012]    The masonry panels are preferably made of a metallic material, such as steel. However, the panels can be made of any material providing the necessary structural, thermal, and other characteristics required in fireplace construction. Also, the panels are preferably sized to cover substantially the entire side, rear and base areas of the cavity frame. Additionally, the panels preferably have a thickness capable of providing adequate structural support to the masonry material installed thereon. 
         [0013]    The panel disposed over the base of the firebox cavity optionally defines an opening therethrough. The opening is preferably disposed near a front edge of the base of the firebox, wherein the front edge of the base is near the front end of the firebox. Additionally, a removable cover can optionally be disposed over the opening. The opening is preferably sized to receive a removable ash dump, which is capable of receiving ashes produced during the burning of logs or other material in the fireplace. The ash dump is preferably configured to be easily removed from the opening and to be easily emptied. The cover and the ash dump are preferably configured to be removed and replaced without the use of any tools. 
         [0014]    The fireplace also includes a plurality of firebrick housings configured to be installed on the masonry panels. For example, the housings can be bolted, screwed, riveted, or welded to the panels. The firebrick housings can optionally be attached to the panels so that they are arranged in a running bond, a herringbone pattern, or other decorative pattern. The housings are preferably disposed such that a gap is between adjacent housings. Optionally, the housings can be disposed so that there is no gap between adjacent housings. 
         [0015]    The firebrick housings are preferably sized to receive a firebrick thereon. However, the housings can optionally be configured to receive any material suitable for use in a fireplace or other high-temperature environment. Additionally, the housings preferably comprise at least one holding member configured to adequately hold a firebrick in the housing. In one embodiment, for example, the holding member is a structure that extends from the wall of the housing. The extending structure is advantageously configured to engage with at least one groove in the firebrick. In another example, the holding member is a plurality of protuberances extending outward from the surface of the housing, configured to receive mortar around the protuberances, and to adhere to a firebrick disposed thereon. In still another example, the housing can be configured to receive and hold a firebrick without the use of mortar or other adhering material. Additionally, mortar is preferably introduced into the gaps disposed between the housings to achieve the look of a traditional masonry fireplace. 
         [0016]    The firebricks of the masonry panels are configured to be coupled to the panels. Preferably, the panels have firebrick housings configured to receive and hold firebricks. A portion of the firebrick is preferably of similar shape as a portion of the housing. For example, both the firebrick and housing can be generally rectangular. In one embodiment, the firebrick comprises the pair of sides, each side having a channel or groove that is configured to receive a portion of the holding member. The channel or groove can have a generally U-shaped or similar cross-section. The groove can extend along a portion of the firebrick. In another embodiment, the groove extends from one side of the firebrick to an opposing side of the firebrick. The masonry panel can comprise bricks having grooves and some bricks without grooves. 
         [0017]    In accordance with another embodiment, factory-built masonry structures are able to be constructed at significantly less cost than traditional masonry structures. The masonry panels are preferably constructed such that the costly layout of the brick pattern is eliminated. Additionally, individual brick housings are preferably incorporated into the panel to advantageously allow fast and accurate construction. For example, the panels can be constructed having the firebrick housings pre-arranged in a specific pattern, such as running bond or herringbone. Moreover, the firebricks supplied with the fireplace are preferably pre-cut and identified as corresponding to a particular housing, advantageously reducing the time, and thus the cost, of construction. For example, the fireplace can be constructed by an individual who may not normally have expert masonry skills, again reducing the construction costs. For example, the fireplace can be constructed by a certified fireplace installer or a homeowner Accordingly, a factory-built masonry fireplace can be constructed to resemble a traditional masonry fireplace at less than 20% of the cost and significant savings in installation time. 
         [0018]    In accordance with another embodiment, the necessary materials for constructing a factory-built masonry fireplace are provided in a kit. The kit preferably comprises a firebox defining a cavity with a frame, the frame having side areas, a rear area, a base area, and a top opening. The kit also comprises a chimney system, wherein the chimney system connects to the top opening of the cavity frame. The kit also comprises a plurality of masonry panels preferably configured to be removably attached to the side areas, rear area and base area of the cavity frame. A plurality of firebrick housings is preferably attached to the masonry panels. Additionally, a plurality of preferably pre-cut firebricks is provided, wherein the firebricks preferably correspond to the plurality of housings. The kit also comprises an amount of high-temperature cement. 
         [0019]    The kit enables the user to easily install the plurality of firebrick housings onto the masonry panels and arrange the housings in a desired pattern, such as running bond or herringbone. Alternatively, the housings can be pre-installed and arranged at a factory prior to delivery of the kit to the user. The user then installs the masonry panels on the side areas, rear area, and base area of the cavity frame. Optionally, the masonry panels and the cavity frame are assembled and pre-installed at the factory. The user can mix the high-temperature cement to prepare mortar material. The user can place the bricks into the housings of the panel, where the firebrick preferably corresponds to the housing. The user can repeat this process with the remaining firebrick housings. Once the user has installed the plurality of firebricks in the plurality of housings, the user can apply mortar material into any gaps between any adjacent firebricks to grout the firebrick assembly. The user can then allow the masonry fireplace cure for a desired amount of time before use. Once the masonry fireplace is properly cured, the user can optionally install a facade around the fireplace, as desired. The facade can be formed of masonry panels having housing configured to receive and hold firebricks. Firebricks can be coupled to the masonry panels to achieve a site built masonry appearance. 
         [0020]    Other objects, advantages, and features of embodiments of the present invention will become readily apparent to those skilled in this art from the ensuing detailed description of preferred embodiments thereof. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0021]      FIG. 1A  is an elevated frontal view of a factory-built fireplace having masonry panels installed therein. 
           [0022]      FIG. 1B  is a side view of the fireplace of  FIG. 1A . 
           [0023]      FIG. 2A  is an exploded view of the fireplace illustrated in  FIG. 1A  illustrating the masonry panels installed on the rear wall, sidewalls and base of the fireplace cavity. 
           [0024]      FIG. 2B  is a top view of a masonry panel for the base of the fireplace having a herringbone pattern. 
           [0025]      FIG. 3A  is a top view of a masonry panel for the base of the fireplace, illustrating the firebrick housings thereon. 
           [0026]      FIG. 3B  is a perspective view of a masonry panel for the fireplace. 
           [0027]      FIG. 4  is a top view of a firebrick housing configured to receive a firebrick. 
           [0028]      FIG. 5  is a sectional view of the firebrick housing of  FIG. 4  along line  5 - 5 . 
           [0029]      FIG. 6A  is a top view of a firebrick housing in accordance with another embodiment. 
           [0030]      FIG. 6B  is a side view of the firebrick housing of  FIG. 6A . 
           [0031]      FIG. 7  is a top view of a firebrick housing in accordance with another embodiment. 
           [0032]      FIG. 8  is a sectional view of the firebrick housing of  FIG. 7  along line  8 - 8 . 
           [0033]      FIG. 9A  is a top view of a firebrick housing in accordance with another embodiment. 
           [0034]      FIG. 9B  is a side view of the firebrick housing of  FIG. 9A   
           [0035]      FIG. 10A  is a top view of a firebrick housing having protuberances. 
           [0036]      FIG. 10B  is a side view of the firebrick housing of  FIG. 10A . 
           [0037]      FIG. 11A  is a perspective view of a firebrick housing. 
           [0038]      FIG. 11B  is a perspective view of a firebrick configured to fit in the housing of  FIG. 11A . 
           [0039]      FIG. 12A  is a perspective view of a firebrick housing. 
           [0040]      FIG. 12B  is a perspective view of a firebrick configured to fit in the housing of  FIG. 12A . 
           [0041]      FIG. 13  is a perspective view of a firebrick having a pair of grooves. 
           [0042]      FIG. 14  is a side view of the firebrick of  FIG. 13 . 
           [0043]      FIG. 15  is an exploded sectional view of a masonry panel for the base of the fireplace illustrating an ash dump. 
           [0044]      FIG. 16  is an elevated frontal view of a factory-built fireplace having masonry panels in accordance with another embodiment. 
           [0045]      FIG. 17  is a perspective view of a masonry storage box. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0046]    With reference to  FIGS. 1A and 1B , a factory-built masonry fireplace  100  is illustrated therein. The fireplace  100  generally comprises a firebox  10  having a front end  12  and a rear end  14 . The firebox  10  defines a cavity  30  and panels  40   b,    50   b,    60   b  are preferably disposed in the cavity  30 . In the illustrated embodiment, the fireplace  100  has a chimney outlet  20 , which is part of a chimney system (not shown). However, the furnace  100  can be vent free, thus not requiring a chimney system. The fireplace  100  can be adapted to burn various types of materials. For example, the fireplace  100  can be a wood and/or gas burning fireplace. 
         [0047]      FIG. 2A  illustrates the fireplace  100  of  FIG. 1A  with the panels  40   b ,  50   b,    60   b  removed. The cavity  30  has a frame (not shown) with a rear area  40   a,  side areas  50   a  and a base area  60   a.  The frame can comprise at least one rail that defines the periphery of the cavity  30 . The frame can optionally comprise a plurality of panels, such as a rear wall  40   a,  sidewalls  50   a  and a base  60   a . Optionally, the panels  40   b,    50   b,    60   b  can comprise the frame areas  40   a ,  50   a ,  60   a.    
         [0048]    The panels  40   b,    50   b,    60   b  are preferably removably attached to the rear area  40   a,  side areas  50   a,  and base area  60   a,  respectively. For example, the panels  40   b,    50   b ,  60   b  can be riveted, bolted, screwed, welded, or connected with other connectors or fasteners to the cavity frame areas  40   a,    50   a,    60   a . In the illustrated embodiment, the panels  40   b,    50   b ,  60   b  are in the form of masonry panels configured to receive a body, such as a firebrick. 
         [0049]    The panels  40   b,    50   b,    60   b  are preferably made of metal. For example, the panels  40   b,    50   b ,  60   b  can be made of steel. Optionally, the panels  40   b,    50   b,    60   b  can be made of a sheet metal commonly used in the fireplace industry. However, the panels  40   b,    50   b,    60   b  can optionally be made of any material providing the necessary structural, thermal, and other characteristics required in fireplace construction. 
         [0050]    The panels  40   b,    50   b,    60   b  are preferably sized to cover substantially the entire frame areas  40   a,    50   a,    60   a,  respectively. Additionally, the panels  40   b,    50   b,    60   b  are preferably configured to provide adequate structural support to masonry material disposed thereon. For example, the panels  40   b,    50   b ,  60   b  can have a thickness capable of providing said structural support. 
         [0051]    According to the illustrated embodiment, the panels  40   b,    50   b,    60   b  comprise a running bond pattern. However, the panels  40   b,    50   b,    60   b  can comprise other patterns, such as a herringbone pattern, as illustrated in  FIG. 23 . 
         [0052]      FIG. 3A  illustrates a panel  60   b  in the form of a masonry panel for the base of the fireplace  100 . The panel  60   b  is configured to receive and hold a plurality of firebricks. According to the illustrated embodiment, a plurality of templates or firebrick housings  70  is preferably removably attached to the panel  60   b . It should be understood that the firebrick housings  70  can be similarly arranged on the panels  40   b,    50   b  disposed on the rear area  40   a  and side areas  50   a  of the firebox cavity  30 . 
         [0053]    In the illustrated embodiment, the plurality of housings  70  are aligned in a running bond pattern. However, the housings  70  may be arranged in other patterns, such as a herringbone pattern. Additionally, according to the illustrated embodiment, the housings  70  are preferably aligned in a row with no gap between the ends of the housings  70 . Also, the housings  70  are disposed such that there is a gap between the rows of housings  70 . Optionally, the housings  70  can be arranged so that there is a gap between the housings  70  forming a row. Also, the housings  70  can optionally be arranged so there is no gap between the rows of housings  70 . 
         [0054]    The housings  70  are preferably attached to the masonry panels  40   b,    50   b,    60   b  with readily available connectors and fasteners (not shown), such as bolts, screws, rivets or welds. 
         [0055]      FIG. 3B  illustrates a panel  60   b  for the base of the fireplace  100 . The panel  60   b  is configured to receive and hold at least one brick. In the illustrated embodiment, the plurality of firebrick housings  70  are attached to the panel  60   b  and are aligned in a herringbone pattern. There can be gaps  102  between the sides or the ends of the housings  70 . Optionally, in some embodiments, there may be no gaps between the housings  70 . Although not illustrated, the panel  60   b  and the housings  70  can be integrally formed. 
         [0056]    At the periphery of the panel  60   b  are edges  104 , each edge having a plurality of openings or holes  106  that are used to couple the masonry panel  60   b  to the fireplace  100 . According to the illustrated embodiment, the edges  104  comprise a flat body having openings  106  configured to receive a screw, fastener, or other suitable device for attaching the panel  60   b  to the fireplace  100 . Thus, to install the masonry panel  60   b,  the panel  60   b  can be placed in the desired location in the fireplace  100  and fasteners can be passed through the openings  106  to secure the panel  60   b  to the fireplace. 
         [0057]    The housings  70  are preferably attached to the masonry panel  60   b  by passing fasteners through at least one opening or hole  108  in each of the housings  70 . In the illustrated embodiment, the housings  70  are attached to a backing of the panel  60   b  and the backing of the panel  60   b  can be sheet metal or other suitable structure for holding the housings  70  which in turn hold firebricks. In one embodiment, each of the housings  70  has a plurality of holes  108  to ensure that the housings remain attached to masonry panel  60   b  when bricks are disposed and held within the housings  70 . Although not illustrated in  FIG. 3B , firebricks can be installed in the housings  70  as discussed below. 
         [0058]    The panel  60   b  in the illustrated embodiment is generally flat. However, the panel  60   b  can have other shapes. For example, the panel  60   b  can preferably comprise at least one flat portion and at least one curved portion. In one embodiment, at least a substantial portion of the panel  60   b  is curved. Those skilled in the art recognize that there are various shapes and configurations to achieve a desired appearance of masonry panel. 
         [0059]      FIG. 4  is a top view of the firebrick housing  70 . The housing  70  is adapted to be attached to a structure and hold a body. The housing  70  can have at least one sidewall  110  and a base  112 . The sidewall  110  and base  112  may cooperate to define a cavity  114 , which is preferably configured and sized to receive a firebrick. In the illustrated embodiment, the housing  70  comprises a pair of sidewalls  110 . In another embodiment not illustrated, the housing  70  comprises one sidewall  110  and the base  112  forming a generally L-shape bracket. 
         [0060]    Each sidewall  110  has an inner surface  116  and a holding member  78   a.  The inner surface  116  defines a portion of the cavity  114 . The sidewall  110  has at least one holding member  78   a  that is configured to engage with a firebrick to hold at least a portion of a firebrick within the housing  70 . The holding member  78   a  has a longitudinal surface or edge  79  that can engage with the firebrick. However, the holding member  78   a  can have any shape that can engage with the firebricks. Optionally, the sidewall  110  can have a plurality of holding members  78   a,  as illustrated in  FIG. 4 . The holding member  78   a  can extend from at least one side of the wall  110 . In one embodiment, for example, the housing  70  has a pair of sidewalls  110 , each sidewall  110  has a pair of holding members  78   a.  The holding members  78   a  extend from the inner surface  116  and into the cavity  114 . Thus, a plurality of holding members  78   a  extend from the walls  110  for engaging the firebrick. The holding members  78   a  can be disposed at various locations along the sidewall  110  to ensure that the firebrick is securely held in the housing  70 . 
         [0061]    The base  112  has several holes  108  that can be used to attach the housing  70  to the panel, such as masonry panel  60   b . However, the base  112  can optionally be welded or attached to the panel  60   b  in any other suitable manner so that the housing  70  can hold a firebrick. In the illustrated embodiment, the base  112  has a generally rectangular shape and is attached to the pair of sidewalls  110 . The base  112  has a pair of opposing side edges that are attached to the bottom edge of the sidewalls  110  and defines the bottom of the cavity  114 . 
         [0062]    The cavity  114  is preferably similar in shape to at least a portion the firebrick which is pre-cut to be received in the cavity  114 . In the illustrated embodiment, the cavity  114  is generally rectangular and configured to receive a similarly shaped firebrick. However, the cavity  114  can be any other suitable shape and size for receiving a firebrick. 
         [0063]      FIG. 5  is a cross-sectional view of the housing  70  shown in  FIG. 4  along line  5 - 5 . A portion of the firebrick  120  (shown in phantom) is shown disposed within the cavity  114 . The holding members  78   a  are located on either side of the firebrick  120  and engage with grooves  122  in the firebrick  120 . 
         [0064]    The firebrick  120  is preferably configured to engage with at least one of the holding members  78   a  to ensure that the firebrick  120  remains in the panel  60   b . In one embodiment, the firebrick  120  has at least one groove  122  along a side  124  of the firebrick  120 . The groove  122  is sized for receiving the end portion  125  of the holding member  78   a  to limit the movement of the firebrick  120 . Preferably, at least a portion of the edge  79  is disposed within the groove  122 . Optionally, the firebrick  120  can comprise a pair of sides  124  and a plurality of grooves  122 . The firebrick  120  can have the groove  122  along one side  124  and another groove  122  along another side  124 . In the illustrated embodiment, for example, the firebrick  120  is generally rectangular and has a pair of sides  124  that are generally parallel and rectangular, each side  124  having the groove  122 . 
         [0065]    The holding member  78   a  in the form of a flange or tab can extend from the wall  110  and engage with the firebrick  120 . The holding member  78   a  has one side connected to the wall  110  and another side having the end  125 . As shown in  FIGS. 3B and 5 , an opening  126  is defined by the holding member  78   a  and the wall  110 . The holding member  78   a  can have a generally curved cross-section, straight cross-section, or any other suitable shape to hold the firebrick in the housing  70 . In the illustrated embodiment, the holding member  78   a  has a cross-section that has a curved portion and straight end portion. The member  78   a  can have a generally uniform thickness. Those skilled in the art recognize that the member  78   a  can have a non-uniform thickness. The member  78   a , for example, can have a thickness that is reduced towards the end  125 . 
         [0066]    The holding member  78   a  has the end  125  that is configured and sized to fit in a portion of the firebrick  120  to thereby hold the firebrick  120 . In the illustrated embodiment, the end  125  of the holding member  78   a  is preferably configured to fit within the groove  122  of the firebrick  120 . However, the end  125  may be configured to fit within a hole or other structure in the firebrick  120  for holding the firebrick. 
         [0067]    The grooves  122  and the holding members  78   a  can be arranged so that the bottom of the firebrick  120  engages with the base  112 . The base  112  can inhibit the movement of the firebrick  120 . However, the grooves  122  and the holding members  78   a  can be arranged so that the bottom of the firebrick  120  and the base  112  are spaced apart so that a cement mixture can be received in the gap between the firebrick  120  and the base  112 . Further, the firebrick  120  and base  112  can be spaced apart so that at least one of the holding members  78   b,    78   c  (described below) are disposed between the firebrick and the base. 
         [0068]      FIG. 6A  and  FIG. 6B  illustrate the firebrick housing. The housing  70  preferably has at least one sidewall  110  having a plurality of holding members  78   a , where at least one holding member  78   a  is located on either side of the wall  110 . 
         [0069]    In the illustrated embodiment, the housing  70  comprises the pair of walls  110 . A first holding member  78   a  is disposed on one side of the wall  110  and a second holding member  78   a  is disposed on the other side of the wall  110 . The walls  110  are spaced apart and configured to receive the firebrick  120  within the cavity  114  and engage with at least one firebrick  120   a,  which is exterior the housing  70 . In other words, the wall  110  engages with the firebricks located on either side of the wall  110 . As in the illustrated embodiment, each sidewall  110  has a pair of holding member  78   a , each holding member  78   a  engages the groove of the firebrick. Although not illustrated, the wall  110  can have a plurality of holding members  78   a  located on one side of the wall  110  and a plurality of holding member  78   a  located on the other side of the wall  110 . 
         [0070]    Gaps  102  can be formed between adjacent firebricks  120  as shown in  FIG. 6B . Cement mixture can be disposed in the gaps  102  to further ensure that the firebricks  120  remain in the masonry panel  60   b . Optionally, the cement mixture can be placed within voids between the firebricks  120 ,  120   a  and the housing  70  to ensure that the firebricks remain securely attached to a masonry panel  60   b . Thus, the holding member  78   a  in combination with a cement mixture ensure that the firebricks  120 ,  120   a  remain securely coupled to the firebrick housings  70 . The housing  70  can comprise a variety of different holding members. For example, the housing  70  can have at least two of the holding members that in combination hold the firebrick  120 . 
         [0071]      FIG. 7  illustrates a firebrick housing  70  that is generally similar to the housing  70  of  FIG. 6 . The firebrick housing  70  has a plurality of holding members  78   a  extending into the cavity  114  configured to engage a firebrick. The housing  70  can have a lip or flange  113  at its upper and lower ends for engaging the ends of the firebrick. The flanges  113  can inhibit movement of the firebrick which is captured by the housing  70 . Thus, the holding members  78   a  and flanges  113  cooperate to ensure that the firebrick remains securely held in the housing  70 . In the illustrated embodiment, the holding members  78   a  prevent the firebrick from being moved away from the base  112  and the flange  113  prevents the firebrick from sliding along the longitudinal axis of the housing  70 . Although not illustrated, there are other suitable structures that can prevent undesirable movement of the firebrick disposed within the housing  70 . 
         [0072]    With respect to  FIG. 8 , the holding members  78   a  are located on each side of the firebrick, shown in phantom. In the illustrated embodiment, the holding member  78   a  is in a form of flange or tab. The tab  78   a  is generally straight and extends at an angle from the wall  110 . The end  125  of the tab  78   a  is preferably adapted to engage with grooves  122  to hold the firebrick. When the brick  120  is held by the housing  70 , flexible walls  110  of the housing  70  can contact and tightly grip the sides  124  of the brick  120 . Further, the bottom of the brick  120  preferably contact the upper surface of the base  112  to reduce movement of the brick  120  relative to the housing  70 . 
         [0073]      FIG. 9A  and  FIG. 9B  illustrate a firebrick housing. The housing  70  preferably comprises at least one sidewall  72  and a base  74  defining a cavity  76 . In one embodiment, the housing  70  has at least two sidewalls  72  extending from the base  74  and defining the cavity  76 , which is generally rectangular in shape and is preferably configured to receive a firebrick. However, the housing  70  is not limited to having at least two sidewalls  72 . In another embodiment, the housing  70  comprises a single sidewall  72 . The sidewall  72  can be formed of metal or other suitable material for holding firebricks. 
         [0074]    The cavity  76  is preferably configured to receive a pre-cut firebrick. However, the cavity  76  can optionally be configured to receive a brick that is not pre-cut. In another option, the cavity  76  can be configured to receive any material suitable for use in a fireplace or other high-temperature environment. In the illustrated embodiment, the base  74  of the housing  70  has a generally rectangular shape. However, the base  74  is not limited to a rectangular shape and can comprise other shapes configured to receive a firebrick of generally similar shape. 
         [0075]    In the illustrated embodiment, a holding member  78   b  is preferably disposed on the base  74  of the firebrick housing  70 . The holding member  78   b  can optionally be removably attached to the base  74  of the housing  70  using any number of connectors or fasteners, such as screws or rivets. In another option, the holding member  78   b  can be welded to the base  74  of the housing  70 . 
         [0076]    The holding member  78   b  is preferably configured to hold a firebrick in the housing  70  in combination with mortar material. In the illustrated embodiment, the holding member  78   b  is a wire mesh. However, the holding member  78   b  can comprise any structure capable of holding a firebrick on the housing  70 . For example, the holding member can comprise a plurality of protuberances  78   c,  as illustrated in  FIGS. 10A and 10B . In another example, the at least one sidewall  72  can comprise the holding member. 
         [0077]    With continued reference to  FIG. 9B , a fastener in the form of a rivot or bolt  75  passes through the base  74  and can connect the housing  70  to the panel  60   b . A head of the bolt  75  is located between the wire mesh  78   b  and the base  74 . However, the bolt  75  can be located in any suitable position for coupling the housing  70  to the base  74 . Optionally, a plurality of fasteners  75  can be used to attach the housing  70  to the panel  60   b.    
         [0078]      FIG. 11A  illustrates a firebrick housing  71  having the sidewall  110  around a portion of its periphery. The housing  71  has the pair of holes  108  for coupling the housing to the masonry panel  60   b.    
         [0079]    The side wall  110  comprises a pair of generally flat bodies at an angle to each other. The walls  110  are configured to engage with a portion of a firebrick. The walls  110  can inhibit movement of the firebrick  120  disposed within the housing  71 . Although not illustrated, housing  71  can comprise a holding member to ensure that the firebrick remains attached to the masonry panel  60   b.    
         [0080]      FIG. 11B  illustrates a firebrick configured to engage with the housing  71  of  FIG. 11A . The firebrick  123  is sized and shaped so that a portion of the firebrick  123  fits within the cavity  114  of the housing  71 . In the illustrated embodiment, the firebrick  123  has a pair of sides  125  that can contact the sides  110  of the housing  71  to inhibit movement of the firebrick  123 . 
         [0081]      FIG. 12A  illustrates another embodiment of a firebrick housing. The housing  73  has a sidewall  110  around a portion of its periphery. The base  112  of the housing  73  is generally triangular and configured to hold a firebrick of generally similar shape. The sidewalls  110  can engage with the outer surfaces  127  of the firebrick  129  (shown in  FIG. 12B ) disposed within the housing  73  to ensure proper alignment of the firebrick. 
         [0082]    With reference to  FIG. 3B , a variety of different shaped housings can be used to form the panel  60   b . For example, housings  70 ,  71 ,  73 , in addition to other shaped housings, can be used to form the herringbone pattern or other desired pattern. Some of the housings can comprise a holding member to ensure that the firebricks remain properly secured in the masonry panel  60   b . The housing  70  can comprise a variety of different holding members, such as holding members  78   a ,  78   b,    78   c.  It is contemplated that those skilled in the art can determine the appropriate type and sized of housing and holding members for a desired pattern of firebricks, structural properties of the panel, and the like. A further advantage is provided where the housings  70  have holes or apertures so that the housings can be conveniently and quickly coupled to masonry panels  60   b  either on site or in the factory. 
         [0083]      FIG. 13  is perspective view of the firebrick  120  similar to the firebrick of  FIG. 5 . As discussed above, the firebrick  120  is configured to fit within the cavity  114  of the housing, such as housing  70 . A portion of the firebrick  120  is preferably of similar shape as a portion of the housing  70 . 
         [0084]    In the illustrated embodiment, the firebrick  120  comprises the pair of sides  124 , each side  124  having the channel or groove  122 . The groove  122  is generally U-shaped. However, the groove  122  is not limited to a U-shape and can comprise other shapes configured to receive a portion of the holding member, such as holding member  78   a . In other embodiments for example, the groove  122  can be V-shaped. 
         [0085]    The groove  122  can extend along a portion of the side  124  or along the entire length of the side  124 . The groove  122  can have a longitudinal axis that is generally parallel to the upper surface  130  and the lower surface  132  of the firebrick  120 . The groove  122 , of course, can be at different locations on the brick  120  depending on the configuration of the housing that the brick is attached to. Further, many of the bricks  120  disposed in the masonry panel  60   b  may not have any groove  122 . In other words, the panel  60   b  can comprise bricks  120  having grooves  122  and some bricks  120  without grooves. 
         [0086]    The firebrick  120  can be coupled to the panel (e.g., the panel  60   b ) by inserting the firebrick  120  into the cavity  114  of a housing (e.g., the housing  70 ) so that the holding member  78   a  contacts and presses against the firebrick  120  as the firebrick passes through the cavity  114 . The holding members  78   a  are pushed away or towards the sidewalls  110  as the brick  120  is inserted into the cavity  114 . When the firebrick  120  reaches the desired position, the ends  125  of the holding member  78   a  move into the groove  122 , preferably when the bottom of the firebrick is near the base  112 , resulting in the firebrick  120  being held by the housing. Thus, the firebrick  120  can be quickly and conveniently installed or assembled by pushing the firebrick into the cavity  114  and against the base  112  and the members  78   a  snap into the grooves  122  thereby securing the brick in the fireplace  100 . Thus, firebrick can be held captive by the panel without the use or mortar or cement. The firebrick can be attached to the fireplace  100 , as shown in  FIG. 1A , without the use of cement. 
         [0087]    Preferably, the firebrick  120  is held by the panel  60   b  so that the firebrick  120  cannot be pulled off of the panel  60   b . Thus, the firebrick  120  can be permanently attached to the panel  60   b  without the use of cement or mortar. Optionally, the firebricks can be coupled to the housings by sliding the ends  125  of the holding members  78   a  into the ends of grooves  122  of the brick. The ends  125  can then be slide along the groove  122  until the brick reaches the desired position. A further advantage is provided where the firebricks can be pre-cut and identified as corresponding to a particular housing, advantageously reducing the time, and thus the cost, of construction. In one embodiment, the brick has indicia or markings that indicate a corresponding housing that is configured to receive that brick. 
         [0088]    Cement or mortar can be used to achieve a traditional site built masonry appearance. For example, after bricks  120  are attached to the panel  60   b,  cement can fill in the spaces between the bricks  120  resulting in a masonry panel that has a traditional masonry appearance. The cement can provide structural support to further ensure that the bricks  120  remain attached to the panels  60   b . Those skilled in the art recognize that there are various methods of attaching bricks  120  the panels and applying cement to achieve the desired appearance. 
         [0089]    As illustrated in  FIGS. 2B ,  3 A, and  15  by the dashed lines, a cover  180  is preferably removably disposed on the base masonry panel  60   b  proximal to an edge  62   b , wherein upon installation of the panel  60   b  in the fireplace  100 , the edge  62   b  is proximal to the front end  12  of the fireplace  100 . The cover  180  is preferably configured to be easily removed from the panel  60   b  without requiring any specific tools for removal. 
         [0090]      FIG. 15  illustrates an exploded sectional view of the base masonry panel  60   b . The cover  180  is removably disposed over an opening  182  defined in the base panel  60   b . In the illustrated embodiment, the cover  180  has a several bricks, or portions of bricks, that match the pattern of bricks formed by the panel  60   b . However, the cover  180  can have other surfaces and designs. Optionally, the cover  180  can have a handle  183  attached to its upper surface. The handle  183  can be used, for example, to move the cover  180  to expose the opening  182 . 
         [0091]    The opening  182  is preferably disposed proximal to an edge  62   b  of the panel  60   b,  wherein the edge  62   b  is proximal to the front end  12  of the fireplace  100  upon installation of the panel  60   b . Material, such as logs, for burning can be located between the opening  182  and the masonry panel  40   b . In the illustrated embodiment, the cover  180  and opening  182  are rectangular in shape. However, the cover  180  and opening  182  are not limited to this shape and can comprise other shapes, such as a square. 
         [0092]    An ash dump  184  is preferably removably disposed in the opening  182  and configured to receive ashes produced by the burning of logs (not shown) in the fireplace  100 . The ash dump  184  is preferably made of metal. Optionally, the ash dump  184  can be made of other materials having the necessary fire resistant characteristics required for use in a fireplace  100 . Preferably, the ash dump  184  is configured to be easily removed from the opening  182 . For example, the ash dump  184  can comprise handles  184   a.  In the illustrated embodiment, the generally rectangular ash dump  184  comprises the pair of handles at its ends. The handles  184   a  can be sized and configured for convenient gripping. The ash dump  184  has an opening  186  at its upper end so that ash can pass through the opening  186  and into the ash dump  184 . Those skilled in the art recognize that the ash dump  184  can comprise any structure configured to allow easy removal of the ash dump from the opening  182 . However, the ash dump  184  is not limited to this shape and can comprise a cross-section having other shapes, such as a square. The ash dump  184  can be used in combination with panels as described herein. 
         [0093]    A further advantage is provided where ashes can be conveniently removed from the cavity  30 . Ashes are produced and accumulate on the masonry panel  60   b  as material (e.g., a wood log) burns in the fireplace  100 . In the illustrated embodiment, the cover  180  can be manually removed exposing the opening  182  and the ash dump  184 . Ash from the cavity  30  can be conveniently swept through the opening  182  so that the ash falls through the opening  186  and into the ash dump  184 . Thus, ash produced from the burning of material can be removed from the cavity  30  and stored in the ash dump  184 . The cover  180  can be replaced to cover the opening  182  for an attractive brick pattern defined by the panel  60   b  and the cover  180 . These steps can be repeated to remove ashes within the cavity  30  for an attractive, ash free, fireplace  100 . In one embodiment, the material, such as wood logs, for burning can be located between the opening  182  and the masonry panel  40   b  so that the cover  180  can be removed and ash can be dumped in the ash dump  184  while the wood logs conveniently remain in the cavity  30 . The ash dump  184  can preferably be removed from the fireplace  100  and emptied while the wood logs remain in the cavity  30 . 
         [0094]    The ash within the ash dump  184  can be conveniently disposed of by removing the cover  180  and exposing the ash dump  184 . The ash dump  184  can be pulled through the opening  182  and removed from the fireplace  100 , preferably without employing tools. The ash dump  184  can be transported to a garbage container (e.g., a trash can) and the ash from the ash dump  184  can be transferred to the garbage container. The empty ash dump  184  can be replaced in the fireplace  100  by passing the ash dump  184  through the opening  182 . The cover  180  can be placed over the opening  182  and the ash dump  184 , thereby hiding the ash dump  184  underneath the cover  180  and the panel  60   b.    
         [0095]      FIG. 16  illustrates another embodiment of a factory built masonry fireplace  100 . The fireplace  100  is in the form of a gas fired fireplace that is vent free. 
         [0096]    The fireplace  100  can have panels defining at least a portion of its face or facade. In one embodiment, the fireplace  100  comprises at least one panel  200  that can be similar to the panels described herein. The panel  200  can define a portion of the opening of the cavity  30 . In the illustrated embodiment, the fireplace  100  comprises an upper panel  200  and a lower panel  202 . The upper panel  200  defines the upper portion of the rectangular opening of the fireplace  100  and the lower panel  202  defines the lower portion of the opening. Firebricks are advantageously coupled to the panels  200 ,  202  for site built masonry appearance. Optionally, the fireplace  100  can have a panel  206  at its lower end. In the illustrated embodiment, the panel  206  defines the hearth of the fireplace  100 . Although not illustrated, masonry panels that are similar to the panels described herein can be used to form a mantel or other portions of a fireplace. 
         [0097]    In practice, the masonry fireplace  100  described above can be constructed using a kit. The kit preferably comprises the firebox  10 , the chimney system (not shown), and the panels  40   b,    50   b,    60   b,  preferably preinstalled in the cavity  30  of the fireplace  100 . The panels  40   b,    50   b,    60   b  preferably have a plurality of firebrick housings (e.g., housing  70 ) pre-installed thereon. The kit also comprises a plurality of firebricks, preferably pre-cut and corresponding to the plurality of housings  70 . The kit can also have an amount of a preferably high-temperature cement mixture. 
         [0098]    A user mixes the high-temperature cement mixture, applies it to a firebrick housing  70  and disposes the corresponding firebrick in the housing  70 . For example, a user can apply the cement to a housing  70  having a wire mesh  78   b  or a plurality of protuberances  78   c  such that the cement is disposed between openings in the wire mesh  78   b  or around the protuberances  78   c.  Optionally, a user can dispose a brick in a housing  70  configured to receive and hold a firebrick without the application of high-temperature cement or other mortar material. The user can then repeat this procedure with the remaining housings  70  to construct the masonry fireplace. Once the user has installed all the firebricks in the corresponding housings, the user can apply the high-temperature cement material to any gaps between adjacent firebricks to grout the gaps. The methods of assembling the fireplace which are described herein are not limited to the exact sequence of acts described, nor is it 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 disclosed embodiments. The panels can be used to achieve site built masonry appearance of indoor and outdoor structures. For example, the fireplace  100  can be can be outdoor fireplace. 
         [0099]    The holding members described herein can be used to couple bricks to various types of structures. As illustrated in  FIG. 17 , the brick panels can form a storage structure  210  in the form of a wood storing box. The structure  210  can be self standing or connected to another structure. For example, the panels can be similar to the panel  60   b  and can form a wood storing box that has an opening  212  for receiving at least a portion of wood logs. In one embodiment, the walls of the box are formed from panels similar to panels  60   b . In the illustrated embodiment, side panels  216  and a front panel  220  can form the vertical walls of the box  210 . Panel  224  forms the bottom of a chamber  225  which is configured to receive wood logs. An upper surface or ceiling  226  defines the upper portion or the ceiling of the chamber  225  and the panel  228  forms the back of the chamber  225 . In the illustrated embodiment, the top  232  of the box  210  is formed of cement. However, the top  232  or any other portion of the box  210  can be formed of the panels described herein. For example, in another embodiment, the entire outer surface of the structure  210  is formed by the panels configured to receive and hold bricks. Bricks can be placed into the panels such that holding members and walls of the panels cooperate to hold the bricks. Thus, the bricks illustrated in  FIG. 17  can be installed with or without the use of cements. Cement, of course, can be applied between the bricks to grout the panels to achieve site built masonry appearance. The storage structure  210  can also be constructed from various types of metals and other materials with suitable characteristics such as plastics, wood, or composite materials. For example, the structure  210  can have a portion made of wood and a portion made of metal. Preferably the bricks are attached to a panel that is similar to panel  60   b  and substantially made of metal. One of ordinary skill in the art can determine the appropriate combination of material type, thickness, and shape to achieve the desired structural characteristics. 
         [0100]    The various embodiments disclosed herein can be used to form fire pits, brick walls, brick counters, and other structures that can be made of bricks. For example, disclosed embodiments can form at least a portion of a countertop of an outdoor barbecue. 
         [0101]    Although the inventions disclosed herein have been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the inventions disclosed herein extend beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the inventions and obvious modifications and equivalents thereof. Thus, it is intended that the scope of the inventions disclosed herein should not be limited by the particular disclosed embodiments described above, but should be determined only by a fair reading of the embodiments that follow.