Abstract: A method of forming articles made of an inorganic fiber material using compression molding. In one respect, a method of forming an article, wherein the method includes providing a molding composition comprising inorganic fiber and an inorganic binder, and compression molding the molding composition into the article. In another respect, the method including providing a molding composition comprising inorganic fibers and a binder, and compression molding the molding composition into the article, wherein at least 75% by weight of the molded article is inorganic material. In some embodiments the cured binder is capable of withstanding temperatures of at least 600° F. without significant degradation or deterioration due to heat. Articles made by the use of such methods and a molding composition for use in compression molding an article are also included.

Abstract: A method of forming articles made of an inorganic fiber material using compression molding. In one respect, a method of forming an article, wherein the method includes providing a molding composition comprising inorganic fiber and an inorganic binder, and compression molding the molding composition into the article. In another respect, the method including providing a molding composition comprising inorganic fibers and a binder, and compression molding the molding composition into the article, wherein at least 75% by weight of the molded article is inorganic material. In some embodiments the cured binder is capable of withstanding temperatures of at least 600° F. without significant degradation or deterioration due to heat. Articles made by the use of such methods and a molding composition for use in compression molding an article are also included.

Abstract: A gas burner includes a monolithic burner panel coupled to a bottom burner member for use as a bottom panel of a combustion chamber enclosure. The burner panel includes at least one aperture for providing a gas/air mixture to a top surface of the burner panel for combustion. The burner panel includes at least one elevated area. The burner panel is a composite material formed from a compression molding process. The burner panel includes elevations that can be shaped into log structures to provide a realistic fire within a fireplace unit, stove, or insert.

Abstract: A gas burner includes a monolithic burner panel coupled to a bottom burner member for use as a bottom panel of a combustion chamber enclosure. The burner panel includes at least one aperture for providing a gas/air mixture to a top surface of the burner panel for combustion. The burner panel includes at least one elevated area. The burner panel is a composite material formed from a compression molding process. The burner panel includes elevations that can be shaped into log structures to provide a realistic fire within a fireplace unit, stove, or insert.

Abstract: A gas burner includes a monolithic burner panel coupled to a bottom burner member for use as a bottom panel of a combustion chamber enclosure. The burner panel includes at least one aperture for providing a gas/air mixture to a top surface of the burner panel for combustion. The burner panel includes at least one elevated area. The burner panel is a composite material formed from a compression molding process. The burner panel includes elevations that can be shaped into log structures to provide a realistic fire within a fireplace unit, stove, or insert.

Abstract: Method of forming artificial logs made of an inorganic fiber material using compression molding are described. One method includes providing a molding composition comprising inorganic fiber and an inorganic binder, compression molding the molding composition into an artificial log, and providing a passageway that is defined by the artificial log and at least one burner aperture that is also defined by the artificial log to pass combustible gas to an outer surface of the artificial log. Artificial log elements and burner structures made by the use of such methods and a molding composition for use in compression molding are also described.

Abstract: A gas burner includes a monolithic burner panel coupled to a bottom burner member for use as a bottom panel of a combustion chamber enclosure. The burner panel includes at least one aperture for providing a gas/air mixture to a top surface of the burner panel for combustion. The burner panel includes at least one elevated area. The burner panel is a composite material formed from a compression molding process. The burner panel includes elevations that can be shaped into log structures to provide a realistic fire within a fireplace unit, stove, or insert.

Abstract: A prefabricated open-ended fireplace box for use in fireplace assemblies is molded from a slurry of refractory ceramic fibers and a non-organic binder. The prefabricated fireplace box is preferably formed in or over a mold which provides an accurate shape to the green or semi-rigid open end box which must be dried or partially fired while on the mold to avoid warping or distortion while being removed from the mold. A rigid surround trim in the form of a C-shape is placed in or on the mold at the open ends of the fireplace box. At least one attachment flange of the surround trim is integrally molded into walls of the fireplace box so that at least the open end of the semi-rigid fireplace box is made rigid when removed from the mold.