Patent Publication Number: US-6659285-B1

Title: Tool for separating coals from ash and method of use

Description:
TECHNICAL FIELD 
     The present invention pertains generally to fireplaces, fireboxes, wood stoves and the like, and more particularly to an improved tool for separating hot coals from ash so that a new fire can be started in a rapid and efficient manner. 
     BACKGROUND OF THE INVENTION 
     With rising energy costs, a renewed interest exists in heating buildings by burning wood, coal and other solid fuels. Concurrently, efforts continue to reduce particulate emissions and gaseous products of incomplete combustion in order to reduce air pollution. The usual pattern of home heating allows a fire to burn down to the level of ashes and coals either overnight, or during the day, at which time it is desirable to restart the fire promptly. One way to do this is to simply place logs on the residual bed of mixed coals and ashes. However most fireboxes perform less efficiently as ashes accumulate in the bottom, and eventually, the ash/coal mixture must be removed. The mixture must either be removed hot, which presents a disposal problem since the heat wafts considerable ash into the room and the mixture serves as an ignition source when discarded, or the fire must be allowed to die down further, which requires a period of time during which no heat is being provided. 
     Then in order to start a new fire, one must use paper or a similar low heat fuel, followed by kindling, and finally by the main fuel, which is usually logs, pellets or coal. Ten to twenty minutes of effort and close attention, plus a large amount of prepared paper and kindling, with a corresponding large amount of poor combustion is needed to use this method. The present invention allows a way to separate the still usable coals from the ashes, so that the ashes can be discarded. The coals can then be used to promptly restart a new fire without the need for paper, kindling or extensive time and attention. 
     Devices for handling the contents of furnaces and for separating coals from ash are well known in the art. For example, U.S. Pat. No. 72,294 shows a cinder shovel. The shovel has a plurality of teeth and can be utilized to transport coal without spilling. 
     U.S. Pat. No. 226,351 illustrates a shovel or scoop for handling potatoes, corn, coal, or other materials which are mixed with dust or dirt. Parallel wires serve as a screen to separate the refuse from the objects. 
     U.S. Pat. No. 229,119 discloses a wire cinder shovel for separating coke and cinders from coal-ashes. The device consists of a shovel having a series of wires fastened by both ends to the handle and an angular wire fastened near a forward portion which serves as a brace. 
     U.S. Pat. No. 1,257,415 comprises a sifting shovel formed of rigid wire. The shovel has a front crosspiece. 
     These existing separator designs were designed primarily for furnaces, where considerable space was available and a push-pull shoveling motion was possible. However, these devices could not function properly in smaller stoves and fireboxes. 
     Alternatively, devices shaped like a common garden rake could be used to separate ash and coal from front to back in the firebox, but even then, they would only work if the depth of the ash-coal mixture is within the range of the rake tines. Furthermore, use of a rake makes it difficult to manipulate the contents forward and back in the confines of a wood stove. 
     One shovel-type device more specifically designed for woodstoves is shown in U.S. Pat. No. 4,305,376 provides a screening and separating action while it removes the ashes from a fire, but it will not operate tightly behind the front lower lip of modern wood stoves, it contains moving parts, and it is designed to replace the standard fireplace shovel. 
     U.S. Pat. No. Des. 285,831 shows a fireplace coal and ash separator which has an elongated shaft, a handle, and a pan having a plurality of slots. 
     U.S. Pat. No. Des. 420,735 describes a fireplace ash and coal separator which has an elongated shaft, a handle, and a shovel portion which has a plurality of fingers connected by a cross member. 
     One further problem exists that is not addressed by the prior art. If ash and coal separation is to be done within a firebox, it is necessary to first move all the ash-coal mixture to one part of the box before separation, in order to have a clear area in which to deposit the separated coals. If this clear area is not provided, then one must dump the separated coals back onto the ash-coal mixture. Therefore, each scoop merely causes a serial dilution of ash content and does not actually result in complete separation. 
     Accordingly, there is a need for a simple ash/coal separation tool that supplements existing fireplace or woodstove tool functions, has the versatility and reliability of a tool with no moving parts, provides access to the ash/coal mixture behind the front lip of the firebox, and allows the entire ash/coal mixture to be moved to one part of the firebox, leaving clear area to deposit the separated coals. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a tool for separating coal from ash and comprises a rigid shaft with a handle at one end and an array of parallel, curved, rigid, round, wire-like elements comprising fingers or tines mounted perpendicularly to each side of the shaft at the other end. The parallel fingers provide the pushing and sifting/separating action. On one side of the shaft, the lengthiest of the parallel fingers have their distal ends bonded to a continuous element running perpendicular to the parallel fingers. On the opposite side of the shaft, parallel fingers protrude that are shorter, and arranged in such a fashion as to serve as a rake. 
     The present invention is specifically tailored to use in the restricted space of a wood stove or fireplace, where the forward scooping action does not work well. 
     The right angle arrangement of the scoop utilizes the powerful and controllable motion of the human forearm that is called supination. This action, which for a right-handed operator results in clockwise rotation of the tool and the forearm, is the same motion that is used to tighten screws with a screwdriver and adjust controls on machinery. It is a much easier and more natural motion than shoveling for work in small spaces. 
     The right angle arrangement of the scoop also allows the scoop to reach the ash/coal mixture immediately behind the front lip of the wood stove or fireplace firebox. This is an area inaccessible to a straight shovel. 
     The right angle arrangement of the scoop formed by the fingers also allows for use as a “pusher” to quickly push the ash/coal mixture to the side, and then sift, separate and transport the coals to the opposite side. Formation of an ash/coal pile with an adjacent clear area, is a key requirement for efficient ahs/coal separation within a firebox. Without a clear area in which to deposit the separated coals, each iteration of the sifting process merely dilutes the ashes and does not achieve good separation. A shovel-type device has a fundamental limitation in being unable to easily move an ash/coal mixture into a pile. 
     The use of round, wire-like parallel tines or fingers in the scoop makes the tool partially self-cleaning. Very little ash sticks to the round elements, as opposed to elements with flat surfaces that tend to accumulate ash. Further, the coals tend not to become trapped between the round parallel fingers as they do with flat, square, rectangular or crisscrossed elements. 
     The use of a continuous round, wire-like leading edge provides smoother sliding action when entering the ash/coal mixture than does an open ended (fork-like) arrangement. The continuous leading edge is light enough that the entire scoop portion still vibrates a bit when tapped against the inside of the firebox, and the vibration is a useful feature to dislodge the rare coal that does become wedged between fingers, or to shake any adherent ash from the tool. 
     The fingers of progressively tapering length on the opposite side of the main shaft are designed to serve as a rake. Because of the front lip of wood stoves, and because of the natural tendency to hold a fireplace tool so that it angles down into a fireplace even if there is no lip, the tapering tines allow the main shaft to be held at a usable angle and still contact the floor of the firebox during a sideways raking action. 
     Advantages of the Invention: 
     1. The tool of the present invention is a simple mechanical tool with no moving parts. 
     2. This tool is reliable 
     3. This tool and technique restart a fire in two to five minutes as opposed to the ten to twenty minutes required with the conventional cleaning, paper and kindling method. 
     4. The fire which is started is much hotter much sooner than a fire started with the paper and kindling method. 
     5. This tool and technique do not require the preparation or storage of paper and kindling. 
     6. Less pollution is generated since low-heat paper and kindling starts are avoided. 
     7. The volume and heat content of the discarded ash material is reduced, making disposal less hazardous. 
     8. This tool and technique save and put to use the heat content of the coals which would otherwise be discarded. 
     9. This tool and technique make use of the powerful supination action of the human forearm, a motion more controllable than axial pushing or other movements. 
     10. The operation is one-handed; it does not require the function of the opposite upper limb. 
     11. This tool and technique supplement the existing standard fireplace tool set. No existing tool is rendered obsolete, and this tool easily hangs on most fireplace tool racks. 
     12. As shown below, this tool and technique allow the lower frontal area of the firebox to be easily cleaned. This area is not readily accessible to shovel-type implements. 
     13. The curved, parallel and properly spaced arrangement of the operating fingers allows the tool to function as both a pusher and a sifter. 
     14. The long rigid fingers, when tapped against the inside wall of the firebox, vibrate slightly and produce a self-cleaning action which shakes loose particles off of the elements. 
     15. The rounded nature of the parallel fingers reduces the likelihood of a coal becoming wedged between the fingers. Any coal that does become stuck is quickly dislodged with a tap of the tool against the inside of the firebox. 
     16. The sifting technique leaves a small amount of smaller material on top of the ash coal pile. The perpendicular member which connects the distal ends of the parallel fingers together, by virtue of being mounted beneath the parallel finger tips, serves a dragging function and can pull this smaller material from the top of the ash coal pile. 
     In accordance with a preferred embodiment of the invention, a tool for separating coals from ash includes an elongated shaft-like body having a first end, an opposite second end, and a longitudinal axis. A handle is disposed at the first end. A plurality of substantially parallel spaced-apart first fingers are longitudinally disposed along the body at the second end. The first fingers outwardly project from the body substantially perpendicular to the longitudinal axis. The first fingers are curved having a concave side and an opposite convex side. Each finger has a distal end, wherein the distal ends of all the fingers are connected by a cross member. 
     In accordance with an important aspect of the invention, the cross member is disposed on the convex side of the first fingers. 
     In accordance with another preferred embodiment of the invention, a plurality of substantially parallel spaced-apart second fingers are also longitudinally disposed along the body at the second end. The second fingers outwardly projecting from body substantially perpendicular to longitudinal axis in an opposite direction from the first fingers. The second fingers each having a different length, wherein the second finger closest to the first end of the elongated body is the longest, and the second finger closest to the second end of the elongated body is the shortest, and the length of each intervening second finger being selected so as to create a substantially tapered rake arrangement. 
     In accordance with an important feature of the invention, the handle has a cross section having a major axis and a perpendicular minor axis, the major axis longer than the minor axis. 
     In accordance with another important aspect of the invention, the cross section of the handle is one of substantially rectangular and substantially oval. 
     In accordance with another important feature of the invention, the major axis forming an angle of between about 70° and about 90° with the first fingers. 
     In accordance with an important aspect of the invention, the first and second fingers having a substantially circular cross section. 
    
    
     Other features and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention. 
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a top plan view of a tool for separating coals from ash in accordance with the present invention; 
     FIG. 2 is a side elevation view; 
     FIG. 3 is an end elevation view; 
     FIG. 4 is an opposite end elevation view; 
     FIG. 5 is a bottom plan view; 
     FIG. 6 is an enlarged cross sectional view along the line  6 — 6  of FIG. 5; 
     FIG. 7 is a cross sectional view of a handle along the line  7 — 7  of FIG. 1; 
     FIG. 8 is a cross sectional view of an oval handle embodiment; 
     FIG. 9 is an end elevation view showing a second handle orientation; 
     FIG. 10 is a reduced top plan view of the tool being utilized as a rake in a firebox; 
     FIG. 11 is a reduced elevation view of coals and ash in a firebox; 
     FIG. 12 is a reduced elevation view of the tool of the present invention being utilized to push the coals and ash into a pile; 
     FIG. 13 is a reduced elevation view of the pile created by the pushing action of the tool, and a clear area in which the coals will be deposited; 
     FIG. 14 is a reduced elevation view of the tool being utilized to remove coals from the pile; 
     FIG. 15 is a reduced elevation view of the tool being utilized to flip the coals into the clear area; 
     FIG. 16 is a reduced elevation view of the coals separated from the ash; 
     FIG. 17 is a reduced elevation view of the tool being utilized to push the coals into the center of the firebox; 
     FIG. 18 is a reduced elevation view of unburned wood placed upon the coals; 
     FIG. 19 is a reduced elevation view of the tool being utilized to drag surface coals from the pile of coals and ash; and, 
     FIG. 20 is a side elevation view of a cross member of the tool being utilized to drag surface coals from the pile of coals and ash. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring initially to FIGS. 1-5, there are illustrated top plan, side elevation, end elevation, opposite end elevation, and bottom plan views respectively of a tool for separating coals from ash in accordance with the present invention, generally designated as  20 . Tool  20  includes an elongated body  22  having a first end  24 , an opposite second end  26 , and a longitudinal axis  32 . In a preferred embodiment, elongated body  22  has a substantially rectangular cross section. A handle  34  is disposed at first end  24 . A plurality of substantially parallel spaced-apart first fingers  36  are longitudinally disposed along body  22  at second end  26 . First fingers  36  outwardly projecting from body  22  substantially perpendicular to longitudinal axis  32 . First fingers  36  are curved and have a concave side  38  and an opposite convex side  40 . Each first finger  36  has a distal end  42 , and the distal ends  42  of all first fingers  36  are connected by a cross member  44  which is disposed substantially parallel to longitudinal axis  32 . Cross member  44  is disposed on convex side  40  of first fingers  36 . In the shown embodiment, cross member  44  comprises a perpendicular extension of the two outside first fingers  36 . In a preferred embodiment, plurality of spaced-apart first fingers  36  define a total width W of between about six inches and about seven inches, and a third length L 3  of between about seven inches and about eight inches. 
     Tool  20  further includes a plurality of substantially parallel spaced-apart second fingers  46  also longitudinally disposed along body  22  at second end  26 . Second fingers  46  outwardly project from body  22  substantially perpendicular to longitudinal axis  32 , in a substantially opposite direction from first fingers  36 . Second fingers  46  each have a different length, wherein the second finger  46  closest to first end  24  of elongated body  22  is the longest, and the second finger  46  closest to second end  26  of elongated body  22  is the shortest, and the length of each intervening second finger  46  is selected so as to create a substantially tapered arrangement. In the shown preferred embodiment, second finger  46  closest to first end  24  has a first length L 1 , and second finger  46  closest to second end  26  has a second length L 2 , wherein first length L 1  is at least twice second length L 2 . Second fingers  46  each have a distal end  48 , the distal ends  48  not being connected to each other, thereby forming a tapered rake configuration. In a preferred embodiment, the plurality of second fingers  46  is equal to the plurality of first fingers  36 , and each second finger  46  is longitudinally aligned with a corresponding first finger  36 . Also in a preferred embodiment of the invention, the plurality of first  36  and second fingers  46  is either eight, nine, or ten. Tool  20  shown in FIGS. 1-5 is designed for use be a right handed person. It may be appreciated that the first  36  and second  46  fingers may be reversed for a left handed person. 
     Referring now to FIG. 6, there is illustrated an enlarged cross sectional view along the line  6 — 6  of FIG.  5 . In a preferred embodiment, first  36  and second  46  fingers have a substantially circular cross section which has a diameter D of about one-eighth of an inch. 
     FIG. 7 is a cross sectional view of handle  34  along the line  7 — 7  of FIG.  1 . Handle  34  has a cross section having a major axis  50  and a perpendicular minor axis  52 , the major axis  50  being longer than the minor axis  52 . Having axis  50  longer than axis  52  better accommodates a grasping hand, and therefore assists in the process of flipping the coals off of tool  20  (refer to FIG.  15 ). Also referring to FIG. 8, in a preferred embodiment the cross section of handle  34  is one of substantially rectangular and substantially oval. Major axis  50  forms and angle A with first fingers  36 . In the shown embodiment, angle A is about 90°. 
     FIG. 9 is an end elevation view showing a second handle  34  orientation. In this embodiment major axis  50  forms an angle A of about 70° with first fingers  36 . This arrangement is useful in imparting a maximum velocity to coals as they are flipped off of tool  20  (also refer to FIG.  15  and the discussion pertaining thereto). Also referring to FIG. 7, an angle A of between about 70° and about 90° is preferred. 
     FIG. 10 is a reduced top plan view of tool  20  being utilized as a rake in a firebox  500 . Because second fingers  46  form a tapered configuration, tool  20  may be placed into the firebox  500  with the distal ends  48  of second fingers  46  all residing on the floor of the firebox  500 , and body  22  not abutting lip  502  of firebox  500 . 
     FIG. 11 is a reduced elevation view of coals  600  and ash  700  in a firebox  500 . After a fire burns down, the fireplace or firebox  500  will contain a mixture of coals  600  and ashes  700 . The larger, solid coals  600  will persist for many hours if the fire&#39;s air intake has been reduced as is customary during overnight or unattended periods. 
     FIG. 12 is a reduced elevation view of the tool  20  of the present invention being utilized to push the coals  600  and ash  700  into a pile. Tool  20  is used to sweep (push) all of the ash/coal mixture in direction  60  to the left side of the firebox  500  (assuming a right handed operator). 
     FIG. 13 is a reduced elevation view of the pile of coal  600  and ash  700  created by the pushing action of tool  20 , and a clear area in which the coals  600  will ultimately be deposited. 
     FIG. 14 is a reduced elevation view of tool  20  being utilized to remove coals  600  from the pile of coal  600  and ash  700 . Tool  20  is inserted more or less horizontally into the ash/coal pile, and with a gentle lift and shake, the coals  600  are lifted up and out of the pile. 
     FIG. 15 is a reduced elevation view of tool  20  being utilized to flip the coals  600  into the clear area of firebox  500 . Tool  20  is then rotated clockwise (for a right handed operator). This flipping action deposits the coals  600  in the right side of the firebox, leaving the ash  700  on the left. Also, a user does not have to rotate the first fingers  36  a full ninety degrees about its handle axis  32  in order to move separated coals  600  over to the clear spot. A quick twist of about 30° degrees, and the coals  600  are tossed neatly over to the empty side of the firebox  500 . The coals seem to be partially launched, and to partially slide down the curved incline of first fingers  36 . 
     The removal and flipping process of FIGS. 14 and 15 is repeated a few times to separate most of the coals  600 . The rake (second fingers  46 ) is then used as necessary for left over coals  600 . As a result of the sifting technique, there will also be a few smaller coals  600  that remain near the top of the primarily ash  700  pile. These can be moved to the right by using cross member  44  on the underside of the tool  20  to laterally drag those surface coals  600  to the coal  600  pile (refer also to FIGS.  19  and  20 ). 
     FIG. 16 is a reduced elevation view of the coals  600  separated from the ash  700 . The ashes  700  are then removed and discarded by means of any standard fireplace shovel or device. 
     FIG. 17 is a reduced elevation view of tool  20  being utilized to push the coals  600  into the center of the firebox  500 . 
     FIG. 18 is a reduced elevation view of unburned wood  800  placed upon the coals  600 . The hot coals  600  will then restart the fire directly without the need for paper or kindling, by placing the solid fuel directly on top of them. 
     FIG. 19 is a reduced elevation view of tool  20  being utilized to drag coals  600  from the pile of coals  600  and ash  700 . 
     FIG. 20 is a side elevation view of the cross member  44  of tool  20  being utilized to drag coals  600  from the pile of coals  600  and ash  700 . The way that the cross member  44  lies below the first fingers  36  allows it to catch and drag the finer coals  600  to the side. 
     In terms of use, a method for separating coals  600  from ash  700 , comprising: 
     (1) providing a pile of coals  600  mixed with ash  700  residing in a firebox  500 ; 
     (2) providing a tool  20  for separating the coals  600  from the ash  700 , the tool  20  having: 
     an elongated body  22  having a first end  24 , an opposite second end  26 , and a longitudinal axis  32 ; 
     a handle  34  disposed at the first end  24 ; 
     a plurality of substantially parallel spaced-apart first fingers  36  longitudinally disposed along the body  22  at the second end  26 ; 
     the first fingers  36  outwardly projecting from the body  22  substantially perpendicular to the body  22 ; 
     the first fingers  36  being curved and having a concave side  38  and an opposite convex side  40 ; 
     each first finger  36  having a distal end  42 ; and, 
     the distal ends  42  of all the first fingers  36  connected by a cross member  44 , the cross member  44  disposed substantially parallel to the longitudinal axis  32 ; 
     (3) grasping the handle  34 ; 
     (4) using the first fingers  36  to push the pile of coal  600  and ash  700  to a first area of the firebox  500 ; 
     (5) inserting the first fingers  36  concave side  38  up into the pile; 
     (6) removing the first fingers  36  from the pile so that a portion of the coals  600  reside on the concave side  38 ; 
     (7) in a supinating action rotating the handle  34  about the longitudinal axis  32  so that the portion of coals  600  are flipped to a second area of the firebox  500 ; and, 
     (8) repeating steps (5) through (7) until the coals  600  have been separated from the ash  700 . 
     The method further including: 
     in step (7), the rotation being at least about 30°. 
     The method further including: 
     (9) as required, using cross member  44  to drag surface coals  600  from the pile. 
     The method further including: 
     the tool  20  for separating the coals  600  from ash  700  further including: 
     a plurality of substantially parallel spaced-apart second fingers  46  longitudinally disposed along the body  22  at the second end  26 ; 
     said second fingers outwardly projecting from the body substantially perpendicular to the body; 
     the second fingers  46  outwardly projecting from the body  22  in a substantially opposite direction from the first fingers  36 ; and, 
     the second fingers each having a different length, wherein the second finger  46  closest to the first end  24  of the elongated body  22  is the longest, and the second finger  46  closest to the second end  26  of the elongated body  22  is the shortest, and the length of each intervening second finger  46  being selected so as to create a substantially tapered arrangement; and, 
     (9) as required, using the second fingers  46  in a raking motion to ensure that all the coals  600  reside in the second area of the firebox  500 . 
     The preferred embodiments of the invention described herein are exemplary and numerous modifications, dimensional variations, and rearrangements can be readily envisioned to achieve an equivalent result, all of which are intended to be embraced within the scope of the appended claims.