Patent Publication Number: US-2020284437-A1

Title: Fireplace with controllable and image-bearing rear wall

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Application Ser. No. 62/814,690 filed on Mar. 6, 2019 and entitled Fireplace With Controllable And Image-Bearing Rear Wall, which is incorporated herein by reference in its entirety and for all purposes. 
    
    
     FIELD OF THE INVENTION 
     The invention relates generally to fireplaces. Embodiments include gas burning fireplaces. 
     BACKGROUND 
     Fireplaces, including fireplaces with combustion chambers that burn gas, are generally known and disclosed, for example, in the following U.S. published patent applications and patents, all of which are incorporated herein by reference in their entirety and for all purposes. 
     
       
         
           
               
               
               
             
               
                   
                   
               
               
                   
                 Application No./Patent No. 
                 Inventor 
               
               
                   
                   
               
             
            
               
                   
                 7,258,116 
                 Searcy 
               
               
                   
                 2008/0168980 
                 Lyons et al. 
               
               
                   
                 2009/0151711 
                 Wells et al. 
               
               
                   
                 2010/0170496 
                 Berg et al. 
               
               
                   
                   
               
            
           
         
       
     
     There remains a continuing need for improved fireplaces. For example, there is a need for fireplaces with enhanced functionality and esthetics. Improved fireplaces that are convenient to operate would be especially desirable. 
     SUMMARY 
     Disclosed embodiments include fireplaces and methods for manufacturing fireplaces. 
     One example is a fireplace comprising a combustion chamber, a front opening allowing viewing within the combustion chamber, a back wall opposite the front opening, a combustion region between the front opening and the back wall adapted to provide a flame, and an opaque and non-homogeneous image on the back wall, wherein the image is visible through the front opening and combustion region when the flame is provided in the combustion region. 
     In some embodiments the back wall includes a glass wall, and the image includes a printed multi-color ink image on the glass wall. The printed ink image may include ceramic ink. The combustion region may include a gas burner. The image may be an image of an outdoor area beyond or in a vicinity of the fireplace. The image may include one of a cityscape and a landscape. The image may include one of a cityscape, a landscape, a brick wall, a wood wall, a tile wall, and a team logo. The image may include a heat-resistant, printed multi-color ink image on the back wall. 
     Another example is a method for manufacturing a fireplace of the type including a combustion chamber, a front opening allowing viewing within the combustion chamber, a back wall opposite the front opening and a combustion region between the front opening and the back wall adapted to provide a flame. The method comprises receiving an electronic file for a non-homogenous image, transferring the electronic file to a printer and causing the printer to print the image on the back wall, receiving the back wall including the printed image, and assembling the back wall including the printed image into the fireplace. 
     In some embodiments receiving the electronic file may include receiving the electronic file for a multi-color image. Transferring the electronic file to the printer may include causing the printer to print the image in ceramic ink on the back wall. Transferring the electronic file to the printer may include causing the printer to print the image on a glass back wall. Receiving the electronic file may include receiving the electronic file for an image including one of a cityscape, a landscape, a brick wall, a wood wall, a tile wall, and a team logo. Receiving the image file may include receiving the image file over the Internet. Transferring the electronic file to the printer may include transferring the image file over the Internet. 
     Another example is a fireplace comprising a combustion chamber, a front opening allowing viewing within the combustion chamber, a back wall opposite the front opening, wherein the back wall can be controllably switched between an opaque state and a transparent state, a combustion region between the front opening and the back wall adapted to provide a flame, and a controller coupled to the back wall enabling a user to switch the back wall between the opaque and transparent states. 
     In some embodiments the back wall comprises a glass panel and switchable film on the glass panel. The controller may be coupled to the switchable film. The opaque state may be a frosted state. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic elevation view of a fireplace including a rear wall in accordance with embodiments. 
         FIGS. 2A and 2B  are isometric views of an example embodiment of a fireplace in accordance with the present disclosure. 
         FIGS. 3A and 3B  are isometric views of the fireplace embodiments shown in  FIGS. 2A and 2B , showing burner and grate assemblies in the combustion chamber. 
         FIG. 4  is an exploded view of the fireplace shown in  FIGS. 1, 2A, 2B, 3A and 3B . 
         FIG. 5  is another exploded view of the fireplace shown in  FIGS. 1, 2A, 2B, 3A and 3B . 
         FIGS. 6A and 6B  are illustrations of a fireplace with an image-bearing rear wall in accordance with embodiments. 
         FIGS. 7A-7H  are examples of images that can be incorporated into the fireplace in accordance with embodiments. 
         FIG. 8  is an illustration of a fireplace with an image-bearing rear wall in a wall of a building in accordance with embodiments. 
         FIG. 9  is a flowchart of an embodiment for manufacturing fireplaces with an image-bearing rear wall. 
         FIG. 10  is a diagrammatic illustration of a controllable/image-bearing rear wall for fireplaces in accordance with embodiments. 
         FIGS. 11A and 11B  are illustrations of a fireplace including a rear wall in accordance with  FIG. 10 , from the front side of the fireplace. 
         FIGS. 12A and 12B  are illustrations of a fireplace including a rear wall in accordance with  FIG. 10 , from the rear side of the fireplace. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  is an example of a fireplace  100  (with the front section cut-away for illustrative purposes) that includes a controllable and image-bearing back or rear wall  207  in accordance with embodiments of the invention. As shown, the fireplace  100  includes a firebox (or combustion chamber enclosure)  150  having a combustion region including a burner  120  and a grate  130 . A combustible gas or fuel, for example natural gas or liquid propane gas, is delivered to the burner  120 , which is located in a combustion chamber  154  that is defined by firebox  150 , where it is then combusted to provide a flame. As described in greater detail below, in embodiments, rear wall  207  can include printed images, such as cityscapes and landscapes, that are visible to a user through a front side access opening  215  and the combustion region. In embodiments, the rear wall  207  can be controllably switched between transparent and opaque states, enabling the user to control whether the combustion region can be viewed from the back side of the fireplace  100  (i.e., from the side opposite the access opening  215 ). 
     Combustion products generated by combustion of fuel at the burner  120  can be exhausted from the fireplace  100  via a venting or air guide arrangement  140 . The illustrated embodiment of venting arrangement  140  includes an upper exhaust guide  142 , where combustion products are removed from the firebox  150  through firebox exhaust outlets  152 . The upper exhaust guide  142  and exhaust outlets  152  cooperate to form a plenum or manifold for collecting combustion products, which can be of any suitable geometric arrangement. The exhaust outlets  152  are located in the upper section of the combustion chamber in embodiments, though any location that allows exhaust gases to be drawn into the exhaust outlets is suitable. The upper exhaust guide  142  fluidly communicates with an exhaust passage  144  that runs from top to the bottom of the firebox  150 . The exhaust passage  144  includes an upper end  143  and a lower end  145 . The upper end  143  of the exhaust passage  144  is in fluid communication with the upper exhaust guide  142 . The lower end  145  of the exhaust passage  144  is in fluid communication with a blower arrangement  160  located outside the firebox  150 . The blower arrangement  160  is located below the upper exhaust guide  142 , and is located below the combustion chamber  154  in embodiments. The blower arrangement  160  includes an exhaust section  162 . The exhaust section  162  is located adjacent an exhaust port  163  in the fireplace  100 . The exhaust port  163  is connected to a ducting arrangement (not shown). Other embodiments of fireplace  100  include other venting arrangements  140 . 
     The blower  160  operates generally when the burner  120  in the fireplace  100  is operating, such that combustion products are taken in the firebox exhaust outlets  152  in the upper exhaust guide  142 . The blower can also continue to run until a temperature sensor in the fireplace senses a pre-set temperature. This allows the blower to run for a time after the fire is extinguished. The combustion products are then moved downwardly from the upper exhaust guide  142  through the exhaust passage  144 . The combustion products are then exhausted from the fireplace  100  through the exhaust port  163  and into an exterior ducting arrangement (not shown) to be exhausted to atmosphere. An advantage of the illustrated embodiment is that the fireplace  100  can be located in a house or other structure unconstrained by the need for a vertical rise to get the natural draft, driven by the buoyant forces of the heated combustion products, of the fireplace  100  venting the combustion products. While in the example embodiment shown the exhaust port  163  is located below the firebox  150 , it can also be located adjacent the firebox  150 . Similarly, while the example embodiment shows the exhaust port  163  passing through a sidewall of the fireplace  100 , the exhaust port  163  could also be placed in other suitable locations, for example, the bottom of the fireplace  100 . The fireplace  100  can be constructed and assembled from formed sheet metal parts that are connected together by sheet metal screws, rivets, spot welds, crimping or other equivalent means of connection, all of which is well-known in the art. 
     Referring to  FIGS. 2A, 2B and 3A, 3B , shown is an example embodiment of a fireplace  200  that can be similar to fireplace  100 . The fireplace  200  includes an outer shell  202  that houses the firebox  250  and other components. Insulation  291  (see  FIG. 4 ) between the outer shell  202  and the firebox  250  keeps the surfaces of the outer shell  202  cool, and may further provide a sound dampening function to reduce noise generated within fireplace  200 . The fireplace  200  also includes a burner assembly  220  in a combustion region of the firebox  250 . The burner assembly  220  creates the flames from combustion of the fuel provided to the fireplace, typically LP or natural gas. A grate  230  is located adjacent to the burner assembly  220  and can hold decorative logs or rocks. The fireplace  200  includes a bottom vent port  263 , which is coupled to an exhaust ducting arrangement to remove combustion products when the fireplace  200  is operating. 
     Referring to  FIGS. 4 and 5 , the firebox  250  is comprised of opposite right  252  and left  253  side panels, opposite top  256  and bottom  258  panels. The panels  252 ,  253 ,  256 ,  258  define a heat or combustion chamber  254  of the firebox  250  that is accessible and viewable through the front or access opening  215  of the fireplace  200 . In embodiments, a transparent glass panel or doors (e.g., that can be open and closed) can be located at or enclosed the access opening  215 . The heat chamber  254  defines a combustion region that contains the gas burner  220  as well as a decorative grate  230  and the gas logs or rocks (not shown) that cover the gas burner  220 . A conventional-gas supply control assembly  219  controlling the supply of gas to the burner  220  is secured to the underside of the firebox bottom panel  258 . Exhaust means exhaust combustion products or fumes from the combustion chamber  254 . 
     The outer shell  202  encloses the firebox  250  and supports the firebox  250  in the outer shell  202  to create a heat exchange volume  248  between the exterior of the firebox  250  and the interior of the outer shell  202 . The outer shell  202  includes opposite left  203  and right  204  side walls, opposite top  205  and bottom  206  walls and the rear wall  207 . The walls are connected together surrounding the firebox  250 . Top  211  and bottom  213  louvers extend between the outer shell  202  side walls  203 ,  204  above and below the access opening  215  of the firebox  250 . Ambient room air is drawn into the heat exchange volume  248  through the bottom vent louver  213  and the heated air is then returned into the room out through the top vent louver  211 . 
     The illustrated embodiment of firebox  250  contains exhaust outlets in the upper part of the firebox  250 . The exhaust outlets  257  fluidly couple the combustion chamber  254  to an upper exhaust plenum  255  formed between the upper panel  205  of the firebox  250  and an upper exhaust guide  270 . Combustion products are pulled into the upper exhaust plenum  255  by operation of a blower  260  (see  FIGS. 4 and 5 ) located adjacent the exhaust port  263 . The upper exhaust plenum  255  is fluidly coupled to a substantially vertical exhaust passage  244  between the upper exhaust plenum  255  and the blower  260 . The exhaust passage  244  allows combustion products to pass from the upper exhaust plenum  255  to the blower  260  and then out the exhaust port  263 , with the combustion products traveling in a downward direction. With the blower  260  operating, combustion products are drawn from the combustion chamber  254  into the upper exhaust plenum  255 , through the exhaust passage  244  and then through the blower  260  and out the exhaust port  263 . Preferably, the combustion products are exhausted from the exhaust port  263  into a ducting arrangement. An advantage is that the blower  260  allows the fireplace  200  to exhaust to a ducting arrangement having an initial horizontally oriented section coupled directly to the exhaust port  263 . An advantage of the disclosed embodiment is that it allows placement and operation of a fireplace that may not otherwise be possible using natural ventilation methods and apparatuses. 
       FIGS. 6A and 6B  illustrate embodiments of a fireplace  200  in accordance with embodiments, that include a printed image on the surface of the rear wall  207  (i.e., the surface facing the access opening  215 . In the embodiments illustrated in  FIGS. 6A and 6B , the image is of a landscape. In embodiments, the image on the rear wall  207  is multicolored, and non-homogeneous (i.e., the image is not a single solid color). As shown, the image is visible through the access opening  215  and is visible behind the flame provided in the combustion region. In embodiments, the rear wall  207  and image are heat resistant to prevent degradation by the flame. The rear wall  207  can, for example, include a glass panel, and the image can be painted or printed on the glass panel using ceramic ink. Other embodiments of the fireplace  200  can include other image-bearing rear walls  207 . As non-limiting examples of such image-bearing rear walls  207 ,  FIG. 7A  shows an abstract image,  FIG. 7B  shows a cityscape image,  FIG. 7C  shows the landscape image in  FIGS. 6A and 6B  in greater detail,  FIG. 7D  shows a team logo image,  FIG. 7E  shows a brick wall image,  FIG. 7F  shows a tile wall image,  FIG. 7G  shows a stone wall image, and  FIG. 7H  shows a wood panel image. 
     The images on the image-bearing rear wall  207  of the fireplace can be selected to match visual aspects of regions surrounding the fireplace  200 . For example, the wood in the wood panel image shown in  FIG. 7H  matches the wood surround  201  around the exterior of fireplace  200  shown in  FIGS. 6A and 6B . The cityscape image of the rear wall  207  of the fireplace  200  shown in  FIG. 8  matches the cityscape visible through the windows  203  in the wall on the opposite sides of the fireplace. 
       FIG. 9  is a flowchart describing a method  300  for manufacturing a fireplace such as  200  in accordance with embodiments. As shown at step  302 , an electronic file for the image to be printed or otherwise applied on the rear wall  207  can be received over a network. In embodiments, the electronic image file can be received by the fireplace manufacturer over the Internet. The electronic file can be of any image desired by a customer, thereby allowing a high degree of customization by the customer. The electronic image file can be transferred to a printer, for example over a network such as the Internet as shown by step  302 . In other embodiments the image file is transferred to the printer over a local network. Other information about the image-bearing rear wall  207 , such as the size of the wall and image to be printed, can also be transferred with the image file. In embodiments, the printer is an entity that is capable of printing images in ceramic ink onto glass plates. Using the received image file, the printer prints the image on the rear wall  207  as shown at step  306 . The printer then sends or transfers the printed image-bearing wall  207  to the location at which the fireplace  200  is assembled as shown by step  308 . In embodiments, a common carrier is used to transport the image-bearing rear wall  207  to the fireplace  200  assembly location. At the assembly location the image-bearing rear wall  207  is assembled with other components to manufacture the fireplace  200  as shown at step  310 . Other methods for manufacturing the image-bearing rear wall  207  and assembling that rear wall into the fireplace  200  are used in other embodiments. 
     Fireplaces such as  200  with image-bearing rear walls  200  can transform a fireplace interior into a unique piece of art with high-definition images of virtually anything that an end-user customer, architect or designer may desire. The fireplaces  200  can be designed to customers&#39; specifications in any size and shape. High-temperature-resistant paint or ink can be incorporated to match any desired design element. Any of a wide range of high definition images can be used, such as for example a beach setting from a stock or original photo used to accent a driftwood log set in the combustion region and natural stone. Exterior (e.g., surround) finishing materials such as brick, stone and tile can be matched with a seamless transition to the interior firebox lining with a relatively efficient installation. 
       FIG. 10  is a diagrammatic illustration of an image-controllable rear wall  207  in accordance with embodiments. As shown, wall  207  includes a transparent glass panel  400  and a switchable film  402  on the panel. A controller  404  is coupled to the switchable film  402 . Switchable films and associated controllers such as  402  and  404  are generally known and commercially available. In embodiments, controller  404  can be used to cause the film  402  to switch between a transparent (e.g., first or off) state that will allow light and images to be viewed through the film, and an opaque (e.g., second or on) state (e.g., including frosted or translucent) that substantially blocks light transmission or at least prevents viewing of images through the film. 
       FIGS. 11A, 11B, 12A and 12B  illustrate embodiments of a fireplace  200  including embodiments of an image-controllable rear wall  207  such as those described in connection with  FIG. 10 .  FIGS. 11A and 11B  illustrate the fireplace  200  from the front side, showing the combustion region and interior of the combustion chamber  254  through the access opening  215 .  FIG. 11A  shows the fireplace  200  with the rear wall  207  in the off or transparent state, with the area behind the fireplace visible through the rear wall (and therefore from the front side through the access opening  215  and combustion chamber  254 ).  FIG. 11B  shows the fireplace  200  with the rear wall  207  in the on or opaque state, substantially blocking visibility of the area behind the fireplace from the front side of the fireplace.  FIGS. 12A and 12B  illustrate the fireplace  200  from the rear or back side (i.e., the side directly facing the rear wall  200 , and opposite the side shown in  FIGS. 11A and 11B ).  FIG. 12A  shows the fireplace  200  with the rear wall  207  in the off or transparent state as in  FIG. 11A , with the interior of the fireplace, including the combustion chamber  254  and flame being visible from the back side.  FIG. 12B  shows the fireplace  200  with the rear wall  207  in the on or opaque state as in  FIG. 11B , with visibility into the interior and combustion chamber  254  of the fireplace substantially blocked. In yet other embodiments of the rear wall described in connection with  FIG. 10 , the rear wall is configured to controllably display non-homogeneous black and white and color images that are visible to a user through the access opening  215 . Images of these types can be provided by imaging structures on the rear wall  207  in response to electronic files representing the images. 
     Embodiments of fireplaces  200  such as those described with reference to  FIGS. 10, 11A, 11B, 12A and 12B  have a see-through chassis. They enable alteration of the fireplace configuration to enhance both the function and privacy by efficient control operation. Fireplaces  200  of these types can have any desired size and shape. Applications include bedroom/bathroom and indoor/outdoor see-through fireplaces. Varying levels of privacy and solitude can be achieved by “softening” the view from one side to another, or one room to another. They can be used as creative design elements to alter viewing area and shape. For example, a company logo, team logo, or business name can be presented for view on command. 
     Although the invention has been described in connection with embodiments, those of skill in the art will recognize that changes can be made in form and detail without departing from the spirit and scope of the invention. For example, rear walls of the types described herein can be used in fireplaces with other structural configurations.