FIREPLACE INSERT

Abstract

An upper support structure has a plurality of spaced apart ribs for supporting fuel and allowing ash to fall between the ribs. A frame supports the upper support structure. A drawer is slidably received in the frame, the drawer having a floor with a plurality of support structures attached thereto and extending upwardly therefrom to define air flow spaces above the floor.

Description

CROSS-REFERENCE TO RELATED CASES

This application claims the benefit of U.S. provisional patent application Ser. No. 63/241,259, filed on Sep. 7, 2021, and incorporates such provisional application by reference into this disclosure as if fully set out at this point.

FIELD OF THE INVENTION

This disclosure relates to fireplaces in general and, more specifically, to fireplace inserts.

BACKGROUND OF THE INVENTION

Fireplaces, particularly open style fireplaces, may rely on gas, solid fuels, or a combination thereof. Where solid fuels are used, a number of particular needs arise. For example, there may be a need to prevent rolling or shifting of fuels. Lighting of solid fuels can be problematic, particularly where gas start capabilities are absent. Fireplaces have the further issue of ash handling and disposal.

What is needed is a system for addressing the above, and related, issues.

SUMMARY OF THE INVENTION

The invention of the present disclosure, in one aspect thereof, comprises a fireplace insert having an upper support structure having a plurality of spaced apart ribs for supporting fuel and allowing ash to fall between the ribs, a frame supporting the upper support structure, and a drawer that is received in the frame, the drawer having a floor with a plurality of tinder support members extending upwardly therefrom to define air flow spaces above the floor.

In some embodiments, the plurality of spaced apart support ribs each comprise a front angled upright and a rear angled upright joined to a middle member. The middle member of each of the plurality of support ribs may be joined to the frame. The frame may comprise at least one transverse member joining to each of the plurality of support ribs. In some embodiments, the frame comprises a pair of transverse members, each joined to each of the plurality of support ribs. The transverse member may each have a pair of spaced apart legs.

In some embodiments, the insert further comprises a pair of drawer slides, wherein one drawer slide is affixed between each respective pair of legs of the pair of transverse members. In some cases, at least one guide member extends from the drawer into a guide channel defined in at least one of the pair of drawer slides. The drawer a front handle and a rear handle, and the guide member may extend from the handle.

In some embodiments, the drawer further comprises a pair of paced apart side walls, a front wall, and a rear wall, all bounding the floor. The front wall may have a fairing extending upwardly therefrom and angling away from the floor. The rear wall may also be angled away from the floor. In some instances, the support members comprises a plurality of elongate members extending upwardly from the floor.

The invention of the present disclosure, in another aspect thereof, comprises a fireplace insert with a frame having a plurality of attached spaced apart ribs each with an upwardly extending front support members and an upwardly extending rear support member joined to a medial portion, and a drawer received in the frame below the plurality of spaced apart ribs, the drawer providing a floor with a plurality of fire starter support structure and defining an ash receptacle.

The drawer may provide a front wall having a fascia angled to match an angle of the upwardly extending front support members. In some cases the frame further comprises a pair of spaced apart frame supports each having a transverse member extending over the drawer with each transverse member joining to each of the plurality of spaced apart ribs at the medial portion thereof. The transverse members may each be supported by a pair of legs, each leg extending downward to join one of a pair of drawer slides receiving the drawer below the support ribs.

The invention of the present disclosure, in another aspect thereof, comprises a fireplace insert with a frame having front and rear transverse members, each supported by a pair of legs joining to one of a pair of spaced apart drawer slides, a plurality of fuel support ribs each joined to the front and rear transverse members along a medial portion thereof, and each having a front upright member and a rear upright member joined to the medial portion thereof, a drawer having spaced apart sidewalls, a front wall, and a rear wall bounding a floor and thereby defining an ash receptacle, and a plurality of support members creating an air flow space above the floor.

Some embodiments, further comprise a removable tray in the receptacle, with the plurality of support members being affixed to the tray.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one embodiment of a fireplace insert according to aspects of the present disclosure.

FIG. 2 is a perspective view of a wood pack tray for the fireplace insert of FIG. 1.

FIG. 3 is a frontal cutaway view of the fireplace insert of FIG. 1.

FIG. 4 is a perspective view of another fireplace insert according to aspects of the present disclosure;

FIG. 5 is a perspective view of an ash drawer for the fireplace insert of FIG. 4.

FIG. 6 is a side view of the ash drawer of FIG. 5.

FIG. 7 is a superior view of the ash drawer of FIG. 5.

FIG. 8 is a rear perspective view of the ash drawer of FIG. 5.

FIG. 9 is a perspective view of a frame for the fireplace insert of FIG. 4.

FIG. 10 is an inside view of the support legs of the frame of FIG. 9.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to FIG. 1, a perspective view of a fireplace insert 100 according to aspects of the present disclosure is shown. The fireplace insert 100 may be used in an indoor fireplace or other location. It may be placed within an open fireplace, behind fireplace doors, or in other configurations. Although the insert 100 is particularly useful in specific embodiments to be utilized to enhance the function of an indoor wood burning fireplace, it is not necessarily limited to this application in all embodiments or use cases.

The insert 100 may comprise a wood support structure 102 affixed to a frame 110 that may slidably or otherwise receive a drawer 104. The drawer 104 may contain a wood pack tray 106. The wood support structure 102 may generally resemble, and function as, andirons. The support structure 102 may comprise a number of support ribs 108 that may be curved upward and the front and rear to support natural logs, engineered wood products, or artificial logs (non-consumed). In some embodiments, each rib 108 comprises a flat support member 120 joined at a rear thereof to a rear angled upright 122 and at the front thereof to a front angled upright 124. The flat support member 120 may be considered a medial portion or a middle member, particularly in embodiments where the support member 120 is not flat. The rear angled upright 122 may be outwardly and upwardly angled away from the support member 120 to direct wood or fuel down toward the support member 120 under gravity. Similarly, the front angled upright 124 may be outwardly and upwardly angled away from the support member 120 to direct wood or fuel down toward the support member 120 under gravity. It should be understood that the flat support members 120 may not be completely flat or level and that they may curve continuously into the rear uprights 122 and/or the front uprights 124. The angles of the front uprights 122 and or rear uprights 124 may be straight or flat on an angle or may have a variable angle so as to be convex or concave upward. The uprights 122, 124 may not have an appreciable angle in all embodiments (e.g., they may be completely upright). The uprights 122, 124 may serve to keep logs or other fuel from rolling off of the support structure 102.

The ribs 108 may be affixed to the frame 110 that elevates the ribs 108 and receives the drawer 104. The frame 110 may comprise a front frame support 132 and a rear frame support 134. Each frame support 132, 134 may comprise legs 134 on either side of the drawer 104. The legs 134 may be joined by transverse members 136. In some embodiments, the transverse members 136 are flat and/or level. Ribs 108 may be fastened to or affixed to transverse members 136, with the ribs 108 providing the front to back spacing between the front frame support 132 and the rear frame support 134, thereby acting as part of the frame 110 itself. Ribs 108 may fasten to transverse members 136 in a number of ways including welding, adhesives, rivers, bolts 126 (as shown), or by other fastening mechanisms known to the art.

The drawer 104 may comprise spaced apart side walls 112, a back wall 114, and a front wall 118, possibly equipped with a handle 118. A floor (out of view) of the drawer 104 may support the wood pack tray 106. The drawer 104 may function as an ash drawer and also as a receptable for fuel such as a wood pack that may be supported on the tray 106. Wood packs may be based upon wood-based fuel pellets contained within a wrapper for ease of handling or lighting. Use of wood pack in the drawer 104 may allow for convenient lighting of fuel stacked upon the support ribs 108. A wood pack or other fuels combusting in the drawer 104 may also allow for artificial logs to be lighted from below and to give off radiant heat and/or light.

FIG. 2 is a perspective view of the wood pack tray 106. The wood pack tray 106 may comprise a generally flat or planar floor 202. The floor 202 may be perforated to allow for mobility of ashes as well as transport of combustion air from below. Support members 204 may be situated on the floor 202 to further promote air flow to a wood pack or other combustion material placed on the tray 106. The support members 204 may comprise tent-like ridges running front to back, but other shapes or configurations are contemplated. Support members 204 may be integral with the floor 202 or may be formed separately and affixed to the floor 202.

The wood pack tray may be removable from the drawer 104 by spaced apart side handles 206. Handles may also be provided elsewhere on the wood pack tray 106. In some embodiments, the handles 206 are part of a frame 207 that supports the floor 202 and possibly provides some elevation of the floor 202 from the floor of the drawer 104.

FIG. 3 is a frontal cutaway view of a fireplace insert 100 according to aspects of the present disclosure. In FIG. 3 a wood pack 301 is shown in place in the drawer 104. Here, the tray 106 is absent and the wood pack 301 rests upon support members 302 provided on the floor 304 of the drawer 104. The support members 302 may be affixed to the floor 304 or may be separate components, possibly with an affixed cross brace (not shown) holding them in position with respect to one another. Air flow spaces 303 can been seen between and adjacent to the supports legs 130 may each provide a drawer slide 310 for receiving the drawer 104.

Referring now to FIG. 4, a perspective view of another fireplace insert 400 according to aspects of the present disclosure is shown. The insert 400 may be used in an indoor fireplace or other location, or placed within an open fireplace, behind fireplace doors, or in other configurations. As with the insert 100 and related embodiments discussed above, the insert 400 is particularly useful in specific embodiments to be utilized to enhance the function of an indoor wood burning fireplace, but it is not necessarily limited to these applications in all embodiments or use cases.

The insert 400 may utilize the same or a similar support structure 102 as the insert 100 with the support structure 102 possibly performing the functions of andirons in a fireplace. The insert 400 also comprises a drawer 404 slidably or otherwise received by a frame 410 below the support structure 102. Additional reference to FIG. 9 provides a perspective view of the frame 410 and support structure 102 without the drawer 404.

The frame 410 may comprise a rear frame support 430 and a front frame support 432. Rear frame support 430 may include a pair of spaced apart legs 434 connected via a transverse member 436. Front frame support 432 may include a pair of spaced apart legs 435 connected via a transverse member 432. Transverse members 436 may be flat and/or level and may join to support structure 102 via the ribs 108 as with the insert 100 described above. Here the ribs 108 joined to the transverse members 436 by spot weld 426 but other fastening mechanisms may be used. The respective legs 434, 435 of the frame supports 430, 432 may be joined on either side of the frame 410 by drawer slides 462, discussed further below.

Referring now to FIG. 5, a perspective view of the ash drawer 404 for the fireplace insert of FIG. 4 is shown. For greater clarity, also provided is FIG. 6, which is a side view of the ash drawer 404; FIG. 7, which is FIG. 7 is a superior view of the ash drawer 404; and FIG. 8, which is a rear perspective view of the ash drawer 404.

The ash drawer 404 may comprise spaced apart sidewalls 412, a back wall 414 and a front wall 416. These may bound a floor 407 to define a receptacle 406 for a fire starter or wood pack. The ash drawer 404 may not have a separate removable tray. A wood pack or other fire starter may be placed in the receptacle 406 (e.g., on the floor 407 within the walls 412, 414, 416) and used to ignite the logs or fuel supported by the support structure 102 above as ash shown in FIG. 4. The drawer 404 then functions as an ash receptacle for burned fuel as it falls through the spaced apart ribs 108. In FIG. 4 an exemplary fire starter wood pack 450 can also be seen below the ribs 108.

In FIGS. 5, 7, and 8 a number of support members 502 can be seen rising above the floor 407. If/when a fire starter is placed on these support members 502 air flow may be provided below the fire starter to improve combustion and fire starting performance (e.g., similar to the system as shown in FIG. 3). The support members 502 may comprise wires or elongate members shaped to keep a bottom of a fire starter elevated above the floor 407 and therefore supplied with combustion air on all sides. The support members 502 may also be configured as triangular (in cross section) ridges rising from or attached to the floor 407. Support members 502 may be welded or otherwise affixed in a central location on the floor 407 or they may not be affixed to the floor 407 (in some embodiments, they may be affixed together, as with a cross brace, to be removable as a single unit). In some embodiments more support members 502 are provided than are illustrated and they may cover more of the floor 407 such that multiple fire starters could be used or to provide a greater range of options for placement of the fire starter.

The front wall 416 may have a fascia or fairing 460 proceeding away and upwardly from the drawer 404. An angle of the fairing 460 may match or be somewhat close to the front angled uprights 124 of the ribs 108 as shown in FIG. 5. The fairing 460 may not extend the full length of the uprights 124. The fairing 460 may serve to prevent ash spillage from the front of the insert 404 and may instead funnel or direct ash back into the receptacle 406.

The drawer 404 may provide a front handle 418 which allows the drawer to be pulled out from the rest of the insert, either completely or part way. A rear handle 504 (best seen in FIG. 8) may provide additional handling purchase when the drawer 404 is removed completely (e.g., for emptying ashes). The rear handle 504 may comprise a length of wire or other elongate member fastened to the rear wall 414 and shaped to be spaced apart from the therefrom to provide a lifting point.

Projecting laterally from the rear wall 414 are a pair of guide members 702. The guide members 702 may be formed from ends of the rear handle 504. In other embodiments, the guide members 702 are separate and may be attached to the side walls 414 or the floor 407.

Referring now also to FIG. 10, an inside view of the support legs 434, 435 of the frame of 410 is shown. For clarity, this view is taken as shown by Arrow A in FIG. 9. The drawer slide 462 can be seen to comprise a lower flat surface 1002 on which the floor 406 of the drawer 404 slides when the drawer 404 is placed into the frame 410. In some embodiments, the drawer slide provides a lower side member 1004 (which may connect to the lower flat surface 1002) and a spaced apart upper side member 1006. The side members 1004, 1006 may be spaced apart to define a guide channel 1008 between them. The guide members 702 project laterally away from the side walls 414 and/or the drawer 404 in general, to fit into the guide channel 1008 to guide the drawer 404 into proper position in the frame 410. A stop 1010 or catch may be defined within the channel 1008 such that the guide members 702 are halted or catch temporarily when the drawer 404 is in a convenient location for placing a fire starter without necessarily being completely removed as when emptying ashes, for example. The drawer 404 may be easily manipulated (e.g., by pressing or elevating the handle 418 slightly) to allow the guide members 702 to clear the stop 1010 for complete removable of the drawer 404. It should be understood that the drawer slide 406 opposite the one shown in FIG. 10 may be construction substantially the same.

As may best be seen in FIGS. 7 and 8, the front wall 416 and the fascia 460 may extend to either side beyond a width of the floor 407. This may allow the front wall 416 and/or fascia 460 to serve as a limit on insertion of the drawer 404 into the frame 410. In another embodiment, insertion is limited instead, or in addition, by a stop in the channel 1008 or a termination of the channel 1008 in one or both of the drawer slides 462. As may be best seen in FIG. 5, in some embodiments, the front wall 416 terminates on either side at approximately the width of the legs 435 on the front frame support 432. The fascia 460 may terminate on either end at approximately the width of the edges of the outermost support ribs 108. The spaced apart sidewalls 412 and rear wall 414 may be of a height such that the just clear the transverse members 436 when the drawer 404 is inserted into the frame 410 to allow for minimal ash spillage. While the sidewalls 412 may be substantially upright (e.g., extending at a right angle from the floor 407) the rear wall 414 may angle outwardly away from the floor 407 to further promote ash capture. In some embodiments, the rear wall 414 extends to or beyond the transverse member 436 of the rear frame support 430 when the drawer 404 is fully inserted.

Components of the various embodiments herein (e.g., the ribs 102, the frame 110/410, and the various components of the drawers 104/404) herein may be formed from steel by casting, stamping, machining or combinations thereof. The components may be coated with a fire-resistant coating. In other embodiments, components may be formed from cast iron and coated or left untreated.

It is to be understood that the terms “including”, “comprising”, “consisting” and grammatical variants thereof do not preclude the addition of one or more components, features, steps, or integers or groups thereof and that the terms are to be construed as specifying components, features, steps or integers.

If the specification or claims refer to “an additional” element, that does not preclude there being more than one of the additional element.

It is to be understood that where the claims or specification refer to “a” or “an” element, such reference is not be construed that there is only one of that element.

It is to be understood that where the specification states that a component, feature, structure, or characteristic “may”, “might”, “can” or “could” be included, that particular component, feature, structure, or characteristic is not required to be included.

Where applicable, although state diagrams, flow diagrams or both may be used to describe embodiments, the invention is not limited to those diagrams or to the corresponding descriptions. For example, flow need not move through each illustrated box or state, or in exactly the same order as illustrated and described.

Methods of the present invention may be implemented by performing or completing manually, automatically, or a combination thereof, selected steps or tasks.

The term “method” may refer to manners, means, techniques and procedures for accomplishing a given task including, but not limited to, those manners, means, techniques and procedures either known to, or readily developed from known manners, means, techniques and procedures by practitioners of the art to which the invention belongs.

The term “at least” followed by a number is used herein to denote the start of a range beginning with that number (which may be a range having an upper limit or no upper limit, depending on the variable being defined). For example, “at least 1” means 1 or more than 1. The term “at most” followed by a number is used herein to denote the end of a range ending with that number (which may be a range having 1 or 0 as its lower limit, or a range having no lower limit, depending upon the variable being defined). For example, “at most 4” means 4 or less than 4, and “at most 40%” means 40% or less than 40%.

When, in this document, a range is given as “(a first number) to (a second number)” or “(a first number)— (a second number)”, this means a range whose lower limit is the first number and whose upper limit is the second number. For example, 25 to 100 should be interpreted to mean a range whose lower limit is 25 and whose upper limit is 100. Additionally, it should be noted that where a range is given, every possible subrange or interval within that range is also specifically intended unless the context indicates to the contrary. For example, if the specification indicates a range of 25 to 100 such range is also intended to include subranges such as 26-100, 27-100, etc., 25-99, 25-98, etc., as well as any other possible combination of lower and upper values within the stated range, e.g., 33-47, 60-97, 41-45, 28-96, etc. Note that integer range values have been used in this paragraph for purposes of illustration only and decimal and fractional values (e.g., 46.7-91.3) should also be understood to be intended as possible subrange endpoints unless specifically excluded.

It should be noted that where reference is made herein to a method comprising two or more defined steps, the defined steps can be carried out in any order or simultaneously (except where context excludes that possibility), and the method can also include one or more other steps which are carried out before any of the defined steps, between two of the defined steps, or after all of the defined steps (except where context excludes that possibility).

Further, it should be noted that terms of approximation (e.g., “about”, “substantially”, “approximately”, etc.) are to be interpreted according to their ordinary and customary meanings as used in the associated art unless indicated otherwise herein. Absent a specific definition within this disclosure, and absent ordinary and customary usage in the associated art, such terms should be interpreted to be plus or minus 10% of the base value.

The term “selective” or “selectively,” unless otherwise indicated, is taken to mean that the operation or function is capable of being performed by the structure or device in reference, but the operation or function may not occur continuously or without interruption. Furthermore, a selective or selectively performed operation may be one that the user or operator of a device or method may choose whether or when to perform, but the function or operation is nevertheless fully operative on or within the relevant device, machine, or method and the same includes the necessary structure or components to perform such operation.

Thus, the present invention is well adapted to carry out the objects and attain the ends and advantages mentioned above as well as those inherent therein. While the inventive device has been described and illustrated herein by reference to certain preferred embodiments in relation to the drawings attached thereto, various changes and further modifications, apart from those shown or suggested herein, may be made therein by those of ordinary skill in the art, without departing from the spirit of the inventive concept the scope of which is to be determined by the following claims.

Claims

1. A fireplace insert comprising:

an upper support structure having a plurality of spaced apart ribs for supporting fuel and allowing ash to fall between the ribs;

a frame supporting the upper support structure; and

a drawer that is received in the frame, the drawer having a floor with a plurality of support members extending upwardly therefrom to define air flow spaces above the floor.

2. The fireplace insert of claim 1, wherein the plurality of spaced apart support ribs each comprise a front angled upright and a rear angled upright joined to a middle member.

3. The fireplace insert of claim 2, wherein the middle member of each of the plurality of support ribs joins to the frame.

4. The fireplace insert of claim 3, wherein the frame comprises at least one transverse member joining to each of the plurality of support ribs.

5. The fireplace insert of claim 4, wherein the frame comprises a pair of transverse members, each joined to each of the plurality of support ribs.

6. The fireplace insert of claim 5, wherein each of the transverse members has a pair of spaced apart legs.

7. The fireplace insert of claim 6, further comprising a pair of drawer slides, wherein one drawer slide is affixed between each respective pair of legs of the pair of transverse members.

8. The fireplace insert of claim 7, further comprising at least one guide member extending from the drawer into a guide channel defined in at least one of the pair of drawer slides.

9. The fireplace insert of claim 8, further comprising a front handle and a rear handle affixed to the drawer.

10. The fireplace insert of claim 9, wherein the guide member extends from the handle.

11. The fireplace insert of claim 1, wherein the drawer further comprises a pair of paced apart side walls, a front wall, and a rear wall, all bounding the floor.

12. The fireplace insert of claim 11, wherein the front wall has a fairing extending upwardly therefrom and angling away from the floor.

13. The fireplace insert of claim 11, wherein the rear wall is angled away from the floor.

14. The fireplace insert of claim 1, wherein the support structure comprises a plurality of elongate members extending upwardly from the floor.

15. A fireplace insert comprising:

a frame having a plurality of attached spaced apart ribs each with an upwardly extending front support members and an upwardly extending rear support member joined to a medial portion; and

a drawer received in the frame below the plurality of spaced apart ribs, the drawer providing a floor with a plurality of fire starter support members and defining an ash receptacle.

16. The fireplace insert of claim 15, wherein the drawer provides a front wall having a fascia angled to match an angle of the upwardly extending front support members.

17. The fireplace insert of claim 16 wherein the frame further comprises a pair of spaced apart frame supports each having a transverse member extending over the drawer with each transverse member joining to each of the plurality of spaced apart ribs at the medial portion thereof.

18. The fireplace insert of claim 17, wherein the transverse members are each supported by a pair of legs, each leg extending downward to join one of a pair of drawer slides receiving the drawer below the support ribs.

19. A fireplace insert comprising:

a frame having front and rear transverse members, each supported by a pair of legs joining to one of a pair of spaced apart drawer slides;

a plurality of fuel support ribs each joined to the front and rear transverse members along a medial portion thereof, and each having a front upright member and a rear upright member joined to the medial portion thereof;

a drawer having spaced apart sidewalls, a front wall, and a rear wall bounding a floor and thereby defining an ash receptacle; and

a plurality of support members creating an air flow space above the floor.

20. The fireplace insert of claim 19, further comprising a removable tray in the receptacle, the plurality of support members being affixed to the tray.