Patent Publication Number: US-9903591-B2

Title: Wood burning fireplace assembly with automatic igniter

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This application is a continuation of U.S. patent application Ser. No. 13/492,585 filed Jun. 8, 2012 entitled WOOD BURNING FIREPLACE ASSEMBLY WITH AUTOMATIC IGNITER, which claims the benefit of U.S. Provisional Patent Application No. 61/494,798 filed Jun. 8, 2011 entitled WOOD BURNING FIREPLACE ASSEMBLY WITH AUTOMATIC IGNITER, both of which are incorporated herein by reference in their entireties. 
    
    
     TECHNICAL FIELD 
     Embodiments of the present invention are directed to fireplace assemblies, and more particularly to wood burning fireplace assemblies, including fireplaces, inserts and stoves. 
     BACKGROUND 
     Conventional wood burning fireplaces are configured to allow a user to load wood and other suitable solid fuel into the firebox in a selected arrangement before lighting the fuel to try to start the fire. Often a user must use a combination of paper, kindling, tinder, paraffin-based fire starter, or the like, to “start the fire” in a manner to cause the larger pieces wood to catch fire and to continue to burn. This manual process of lighting the fire can be time intensive, require multiple other materials, and can be frustrating if the fire won&#39;t “start” sufficiently to fully ignite the cut logs, rounds, or other larger pieces of wood. After the wood or other solid fuel has been ignited when initially manually starting the fire, the fuel often does not continue to burn and the fire will go out. Accordingly, the user must try to restart the fire and continue to tend the fire until the fuel is sufficiently hot so as to continue to burn without going out prematurely. There is a need for a system to assist in starting and maintaining a fire at a wood burning or other solid fuel burning fireplace assembly. 
     SUMMARY 
     The present invention is directed to a solid fuel burning fireplace assembly with an automatic ignition system that overcomes drawbacks experienced in the prior art and that provides additional benefits. In accordance with one embodiment, a fireplace assembly is provided for burning solid combustible fuel material. The fireplace assembly comprises a firebox having walls that define an interior area, and an igniter assembly coupled to the firebox. The igniter assembly contains a heating element. The assembly has an ignition end that extends through an aperture in one wall of the firebox. The ignition end is positioned in direct communication with the interior area, wherein the fuel material can be immediately adjacent to the ignition end. The igniter assembly has a rear portion exterior of the fire box. The rear portion has first and second connectors. The first connector is coupled to the heating element and is coupleable to power source. The second connector is coupleable to an air source and is positioned to provide air flow over the heating element and out of the ignition end and into the firebox for impingement with the combustible fuel. 
     A temperature sensor is connected to the igniter assembly and is configured to monitor the temperature within the firebox. A controller is operatively coupled to the igniter assembly and the temperature sensor. The controller controls operation of the heating element, the temperature sensor, and the air flow through the igniter assembly. The controller can activate and deactivate the igniter assembly based upon the temperature within the firebox as sensed by the temperature sensor. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a rear isometric view of a wood-burning fireplace assembly with an automatic igniter system in accordance with aspects of the present invention. 
         FIG. 2  is a top plan view of the wood-burning fireplace assembly with an automatic igniter system  FIG. 1 . 
         FIG. 3  is an enlarged cross-sectional plan view of the wood-burning fireplace assembly taken substantially along on line  3 - 3  of  FIG. 1 . 
         FIG. 4  is front elevation view of the wood-burning fireplace assembly with an automatic igniter system of  FIG. 1 . 
         FIG. 5  is a front elevation view of a wood-burning fireplace assembly with an automatic igniter system in accordance with another embodiment. 
         FIG. 6  is an enlarged cross-sectional plan view of the wood-burning fireplace assembly taken substantially along on line  6 - 6  of  FIG. 5 . 
         FIG. 7  is a side elevation of the wood-burning fireplace assembly of  FIG. 5 . 
         FIG. 8  is an enlarged, partially cut away isometric view of the assembly of  FIG. 5  showing the igniter extending through a side wall. 
     
    
    
     Appendix A includes photographs of embodiments of the wood-burning fireplace assembly and features thereof. 
     DETAILED DESCRIPTION 
     The present disclosure describes solid fuel-burning fireplace assembly, such as a wood burning fireplace assembly, with an automatic igniter system in accordance with certain embodiments of the present invention. Several specific details of the invention are set forth in the following description and the Figures to provide a thorough understanding of certain embodiments of the invention. Many of the details, dimensions, angles, relative sizes of components, and/or other features shown in the Figures are merely illustrative of particular embodiments of the disclosure. Embodiments can have other details, dimensions, angles, sizes, and/or features without departing from the spirit and scope of the present disclosure. Moreover, certain features described with reference to specific embodiments may be combined with other embodiments of the disclosure. Other details describing well-known structures and components often associated with fireplace assemblies and methods of forming such assemblies, however, are not set forth below to avoid unnecessarily obscuring the description of various embodiments of the disclosure. One skilled in the art, however, will understand that the present invention may have additional embodiments, and that other embodiments of the invention may be practiced without several of the specific features described below. 
       FIGS. 1-4  are views of a wood-burning fireplace assembly  10  with an automatic igniter system  12  in accordance with one embodiment. The wood-burning fireplace assembly  10  of the illustrated embodiment has a fireplace housing  14  containing a firebox  16  ( FIGS. 3 and 4 ). The firebox  16  is defined by a back wall  18 , sidewalls  20 , a top wall  22 , and a bottom wall  23  all of which are sealably connected to each other to define an interior area  26 . The front of the firebox  16  is closable by a door  24 . The interior area  26  is configured to receive wood or other solid combustible fuel material and to contain the fuel when burning. The illustrated fireplace assembly  10  is a freestanding stove, although other embodiments can include fireplaces, inserts, or other stoves. 
     The assembly  10  of the illustrated embodiment includes an igniter assembly  30  coupled to the firebox  16  and configured to ignite the wood or other fuel within the firebox  16  so as to start a fire in the fireplace unit or to keep the fire going within the firebox  16 , especially just after a fire is started and while the firebox  16  is not yet fully warmed up. The igniter assembly  30  includes a mounting assembly  32  attached to the wall of the firebox  16 . In the illustrated embodiment, the mounting assembly  32  is mounted on the back wall  18  of the firebox  16 , although the mounting assembly  32  can be mounted to other portions of the firebox  16  or to the fireplace housing  14  in other embodiments. The mounting assembly  32  is connected to and supports an igniter  34  in a selected location and orientation relative to the firebox  16  and the interior area  26 . As best seen in  FIGS. 3 and 4 , the igniter  34  has an ignition end  36  that extends through an aperture  38  in the firebox&#39;s back wall  18 , such that the ignition end  36  is located within or in direct communication with the interior area  26  in the firebox  16 . The igniter  34  is configured to provide an ignition source, such as superheated air or other air source that generates sufficient heat to ignite the wood/fuel or to facilitate continued burning. In one embodiment, the aperture  38  through which the ignition end  36  of the igniter  34  extends is sealed so as to prevent exhaust from passing through the aperture  38  during operation of the fireplace assembly. Such a sealed arrangement is used when the fireplace assembly  10  includes a direct vent fireplace assembly. 
     The igniter  34  is mounted relative to the firebox so as to direct the superheated air downwardly toward the fuel area within the firebox  16  to facilitate initial combustion or continued combustions. The igniter  34  in other embodiments can be aimed in other manners as appropriate for the fireplace assembly. The ignition end  36  of the igniter  34  is positioned adjacent to the back wall  18  without projecting extensively into the firebox  16 , thereby protecting the igniter&#39;s ignition end  36  from being damaged, for example, when wood or other fuel is added into the firebox  16  during operation of the fireplace assembly  10 . 
     The igniter  34  of the illustrated embodiment in an electrical igniter that contains an electrical heating element that, upon activation, glows red-hot and generates sufficient heat to ignite the wood/fuel. In one embodiment, the igniter  34  is a Model HAC0030, manufactured by Tempco Mfg. A rear portion  40  of the igniter is exterior of the fire box and mounted to the mounting assembly  32 . The rear portion  40  of the igniter  34  includes electrical connectors  42  that couple the igniter&#39;s electrical element (not shown) to a power source. 
     The rear portion  40  of the igniter  34  also includes a nipple  44  configured to attach to an air line  48 , which is connected to an air supply  36  or other selected air source. In the illustrated embodiment, the air supply  46  is mounted to a support structure  50  attached to the back of the firebox  16 . In other embodiments, the air supply  46  and/or the support structure  50  can be mounted in other locations while being coupled to the igniter  34  as described above. 
     The air supply  46  is configured to blow air through the air line  48 , through the nipple  44 , and through the igniter so the air flows over the heating element upon activation of the igniter assembly  30 . The flow of air passing over the igniter&#39;s heating element is directed out of the igniter&#39;s ignition end  36 , thereby driving superheated air into the firebox  16  and against the wood or other fuel therein. 
     The igniter  34  and the air supply  46  are operatively connected to a controller  60 , which is configured to control operation of the igniter assembly  34 . The controller  60  can be activated so as to control the igniter  34  and the air supply  46  via controls mounted on the fireplace assembly  10  and/or via a remote control device that wirelessly communicates with the controller  60 . The controller  60  of the illustrated embodiment can be a Viking Model RC2A Remote Touch Tone Relay Controller manufactured by Viking Electronics of Hudson, Wis. Other embodiments can use other controllers. 
     The controller  60  can be configured to provide a plurality of operation modes of the igniter assembly  30 . For example, the controller  60  in one embodiment is configured with a “start mode” for use when initially starting a fire in the firebox. In the start mode, the controller  60  activates the igniter  34  and the air supply  46  so as to provide a substantially continuous flow of superheated air into the firebox that blows against the wood/fuel therein until the wood/fuel is heated to its ignition temperature, thereby starting the wood/fuel to burn. The air supply  46  and the igniter  34  remain on for a selected period of time to ensure that the fire is started in the firebox  16 . 
     In one embodiment, the “start mode” can end after the fire has started or after a selected time period has elapsed. In another embodiment, the “start mode” can include a post-start, “sustain mode” wherein the air supply  46  and igniter  34  are cycled off and on for selected time periods after the fire is initially started to cyclically provide the superheated air to the fuel that will support continued burning of the fuel in the firebox  16 . In another embodiment, the “sustain mode” can be a distinct mode separate from the “start mode” that a user can select when activating the ignition system  30 . The controller  60  can also include other modes, such as a “new fuel mode,” wherein the igniter  34  and air supply  46  may be activated continuously or cyclically for one or more selected periods of time when or just after new fuels has been added into the firebox  16 . The controller  60  can also be configured to independently activate the air supply  46  when the igniter  34  is turned off, thereby directing a flow of non-heated focused combustion air to the burning fuel. Accordingly, the air supply  46  can be used as a focused air flow to “fan the fire.” 
     In one embodiment, the igniter assembly  30  can include or be connected to one or more temperature sensors  62  coupled to the controller  60  that monitor the temperature within the firebox  16 . The controller  60  can activate or deactivate the igniter  34  based upon the temperature within the firebox  16  as sensed by the temperature sensor(s). For example, if the temperature within the firebox  16  is below a threshold level, the controller  60  can activate the igniter  34  and air supply  46  so as to initiate and/or sustain combustion of the fuel in a firebox  16  until the temperature in the firebox has exceeded the threshold level. After the sensors  62  indicate that temperature has exceeded the threshold level, the controller  60  can deactivate or turn off the igniter  34  and/or the air supply  46 . In one embodiment, if the temperature sensors indicate that the temperature within the firebox  16  drops below load a threshold level, the controller  60  can reactivate the igniter assembly  30  so as restart or keep the fire burning in the firebox  16 . The controller  60  can also be configured to turn off the igniter assembly  30  if, as an example, a selected amount of time has elapsed and if the temperature in the firebox  16  has not exceeded the threshold level, which may indicate that there is no longer enough wood or other fuel in the firebox to sustain a fire. 
     The illustrated embodiment shows a single igniter assembly  30  mounted to the back of the firebox  16 . Other embodiments can include a plurality of igniter assemblies coupled to one or more controllers  60 . Each igniter assembly  30  can be connected to a dedicated air supply. In other embodiments, multiple igniters  34  can be coupled to a single air supply. 
     The controller of the igniter  34  is mounted to the back wall and oriented so as to direct the superheated air downwardly toward the fuel area within the firebox  16  the igniter  34  in other embodiments can be aimed in other manners as appropriate for the fireplace assembly. The ignition end  36  of the igniter  34  is positioned adjacent to the back wall  18  without projecting extensively into the firebox  16 , thereby protecting the igniter&#39;s ignition end  36  from being damaged for example when wood or other fuel is added into the firebox  16  during operation of the fireplace assembly  10 . 
       FIGS. 5-8  are views of a wood-burning fireplace assembly  10  with an automatic igniter system  12  in accordance with an alternate embodiment. In this alternate embodiment, the automatic igniter system  12  includes the mounting assembly  32  and the igniter  34  mounted to a side panel  72  of the fireplace housing  14 . The side panel  72  can be a separate panel spaced apart from one of the side walls  20  of the firebox  16 . The side panel  72  has an aperture  74  and the adjacent sidewall  20  has a coaxial the aligned aperture  76  through which the igniter  34  extends. In this embodiment, the ignition end  36  of the igniter  34  is positioned adjacent to the sidewall  20  of the firebox  16 , and the igniter  34  is aimed at so as to direct the flow of air on to the wood or other fuel in the firebox  16  as discussed above. The aperture  76  in the sidewall  20  of the firebox  16  can be sealed to maintain a substantially sealed firebox during operation of the fireplace assembly  10 . 
     In this alternate embodiment, the igniter  34  is connected to an air supply  46  and a controller  60  in a manner similar as discussed above, and the controller  60  is configured with one or more of the operational modes that a user can select to start or maintain a fire in the firebox. In the illustrated embodiment, a single igniter assembly  30  is provided on one side of the fireplace assembly  10 . In another embodiment, an igniter assembly  30  can be provided on each side of the fireplace assembly  10 . In yet another embodiment. 
     In operation, when a user wants to start a fire in the fireplace assembly  10 , the user opens the door  24 , places wood, kindling, paper, or other fuel in the firebox  16  in alignment with the ignition end  36  of the igniter, thereby preparing or “setting” the fire. While the user is setting the fire, the igniter assembly remains in an “off” condition. The door  24  or the firebox  16  may be configured with one or more sensors connected to the controller  60  to determine if the door is open or fully closed. The controller  60  can be configured to activate the igniter  34  only is the door  24  is fully closed. The igniter  34  will be automatically turned off when the door  24  is opened. 
     After the user has set the fire and fully closes the door  24 , the user activates the controls on the fireplace assembly  10  or on a remote controller, so as to select an operation mode of the igniter assembly  30 . For example, the user can select the “start” mode, wherein the controller  60  actives the air supply  46  and the igniter  34  to direct heated air into the set fuel until the temperature of the fuel increases to or past the ignition or flash point, thereby causing the fuel to catch fire. The user can also select an operation mode wherein the igniter assembly  30  is automatically intermittently turned on and off so as to ensure that the fuel continues to burn. In another embodiment, the user can manually light the fire in the firebox  16  before closing the door  24 , and after the door  24  is closed, the igniter assembly  30  can be activated in a “sustain” mode to direct the superheated air to the fuel to keep the fire burning. After the fire is going continuously and/or when the temperature in the firebox  16  has exceeded a threshold level, or after a predetermined time period has elapsed, the controller  60  can automatically turn off the igniter assembly  30 . 
     From the foregoing, it will be appreciated that specific embodiments of the invention have been described herein for purposes of illustration, but that various modifications may be made without deviating from the invention. Additionally, aspects of the invention described in the context of particular embodiments or examples may be combined or eliminated in other embodiments. Although advantages associated with certain embodiments of the invention have been described in the context of those embodiments, other embodiments may also exhibit such advantages. Additionally, not all embodiments need necessarily exhibit such advantages to fall within the scope of the invention. Accordingly, the invention is not limited except as by the appended claims.