Abstract: A gas burner for a fireplace includes a rectangular, unitary pan which is fabricated from a generally rectangular single sheet metal panel. Prior to forming the panel into the pan, an inlet tube hole and gas ports are machined into the panel. Assembled to the unitary pan is a gas inlet tube with an air adjustment sleeve assembled thereto. An optional baffle may be used and the purpose of the baffle is to reduce the back firing of gas. The fabrication steps for converting the flat sheet metal panel into the unitary pan involve forming first and second long edges with specific bend geometries and then folding the panel so as to bring those formed edges into alignment with each other. Those formed edges are then crimped together. Once this is completed, each shorter side edge is then folded to itself and crimped so that on three sides of the unitary pan there are crimped seams which are leak-free and along the fourth side there is a fold.

Abstract: A vent-free, gas fireplace for providing heat, light, and an aesthetic view includes an outer shell arranged with a top panel, front panel, rear panel, and left and right side panels and a combustion chamber positioned within the outer shell so as to define a plurality of air chambers. The combustion chamber is arranged with a primary combustion portion for initial combustion of the gas which is supplied to the fireplace and a secondary combustion portion which includes a catalytic converter and which is designed to bum the emissions from the primary combustion portion. The plurality of air chambers defined between the outer shell and combustion chamber include a rear chamber and a top chamber and positioned within the top chamber is a heat shield which defines an interior volume. The interior volume of the heat shield is in flow communication with the rear chamber so as to direct air through the heat shield and out into the room.