FIREPLACE GRATE

Abstract

According to an embodiment, a fireplace grate is disclosed. The fireplace grate includes a plurality of cross bars, a plurality of support bars, and a plurality of fasteners. The plurality of support bars and the plurality of cross bars can be nested together in a disassembled configuration. Each fastener is configured to extend through a hole in one of the cross bars and engage a corresponding threaded hole in one of the support bars so that each cross bar can be fastened to the plurality of support bars in an assembled configuration with each cross bar spanning the plurality of support bars. A width of the fireplace grate in the disassembled configuration is less than 50% of a width of the fireplace grate in the assembled configuration.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This Application is a Continuation-in-part of application Ser. No. 17/899,337 filed on Aug. 30, 2022, which claims the benefit of U.S. Provisional Application 63/239,047 filed on Aug. 31, 2021, each of which is herein incorporated by reference in its entirety.

SUMMARY

Embodiments of the present disclosure provide for a fireplace grate that is assembled by the end user, thereby providing a full-size fireplace grate that can be shipped and displayed on store shelves with a relatively compact size.

In one embodiment, a fireplace grate includes a plurality of cross bars, a plurality of support bars and a plurality of fasteners where each fastener is configured to extend through a hole in one of the cross bars and engage a corresponding threaded hole in one of the support bars and in a disassembled configuration a width of the fireplace grate is less than 50% of a width of the fireplace grate in the assembled configuration.

In another embodiment, at least one of the cross bars is mounted in a manner whereby it is not perpendicular to the support bars.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only exemplary embodiments and are therefore not to be considered limiting of its scope, may admit to other equally effective embodiments.

FIG. 1 is a perspective view of a fireplace grate in an assembled configuration according to an embodiment;

FIG. 2 is a perspective view of the fireplace grate in a packaged and disassembled configuration;

FIG. 3 is a partial perspective view of the fireplace grate showing an assembly procedure;

FIG. 4 is a partial cross section view of the fireplace grate showing details of a connection point;

FIGS. 5A-C include perspective views of alternative sizes of the fireplace grate;

FIG. 6 is a perspective top view showing an alternative embodiment;

FIG. 7 is a perspective bottom view of the embodiment of FIG. 6;

FIG. 8 is a top view of the embodiment of FIG. 6.

FIG. 9 is a front view of the embodiment of FIG. 6; and

FIG. 10 is a perspective view of the fireplace grate of FIG. 6 in a packaged and disassembled configuration.

To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements and features of one embodiment may be beneficially incorporated in other embodiments without further recitation.

DETAILED DESCRIPTION

Embodiments of the present invention generally related to a fireplace grate that may be suitable for holding logs and the like in a fireplace, but can be shipped and provided on retail shelves in a relatively compact format.

FIGS. 1 and 2 illustrate a fireplace grate 100 according to an embodiment. In FIG. 1, the fireplace grate 100 is in an assembled configuration. In FIG. 2, the fireplace grate 100 is in a packaged and disassembled configuration.

As can be seen in FIG. 1, the components of the fireplace grate 100 include a plurality of cross bars 102 that are each attached to two support bars 104 that run perpendicular to the cross bars. In the example configuration shown in FIG. 1, the fireplace grate 100 includes four cross bars 102 but the number of cross bars may be different in some embodiments depending on a desired length for the fireplace grate 100 and the desired spacing between the bars. Each cross bar 102 is attached to the support bars 104 with fasteners 106. In the assembled configuration of FIG. 1, the fireplace grate 100 can support logs and the like while providing sufficient airflow for suitable use in a fireplace.

FIG. 2 is a perspective view of the fireplace grate in a packaged and disassembled configuration. Each of the cross bars 102 and the support bars 104 are placed in a nested arrangement that minimizes the overall footprint of the disassembled configuration. In this nested arrangement, the crossbars 102 and support bars 104 can be arranged in a box 108. The box 108 in FIG. 2 is shown as transparent in order to illustrate the arrangement. The fasteners 106 are also arranged in the box and a tool 110 is also provided. The tool 110 is provided so that a user can easily assemble the fireplace grate 100 without any additional hardware. The tool 110 is configured to engage each fastener 106 and in the embodiment shown, the tool 110 is a hex wrench shaped to engage a hex head of each fastener 106.

As can appreciated, the fireplace grate 100 in its disassembled configuration greatly minimizes the height of the box containing the components. For example, the box 108 holding the entire fireplace grate 100 in the disassembled configuration may have a height more than 50% less than a height of the fireplace grate 100 in the assembled configuration. According to one embodiment, the height of the box 108 is less than 33% of the height of the fireplace grate 100 in the assembled configuration.

As shown in FIG. 2, the height of the box 108 may be determined by the width of the cross bars 102 and support bars 104 (which may all have the same width) in the nested arrangement. The length of the box 108 may be determined by the length of the longest component, namely, the length of one support bar 104. The width of the box 108 may be selected based on the combined thickness of the cross bars 102 and support bars 104 in the nested arrangement, with additional width for the curved ends of the outermost cross bar 102 in the nested arrangement. The assembly hardware, namely the fasteners 106 and tool 110 do not add to the width of the box, because the assembly hardware can be packaged in the box 108 in available space between the curved ends of the outermost cross bar 102.

The packaged and disassembled configuration of the fireplace grate 100 is significantly more compact than the assembled configuration. For example, in one embodiment, the height of the assembled configuration of the fireplace grate 100 may be around 4 inches, while the height of the box 108 holding the fireplace grate 100 in the packaged and assembled configuration may be around 1.3 inches. As explained above, the width of the box 108 need only to accommodate the combined thickness of each of the cross bars 102 and support bars 104, with additional width to accommodate the curved ends of one of the cross bars 102.

The relatively compact size of the box 108 and the packaged and assembled configuration of the fireplace grate 100 allows a large number of fireplace grates 100 to be stacked significantly more efficiently compared to a traditional fireplace grate. Thus, storage volume is significantly reduced, which reduces shipping costs because, for example, more fireplace grates 100 can be shipped in a single shipping container. Likewise, a retailer can provide a larger inventory supply on a given retail shelf space. Furthermore, the user can more conveniently handle the fireplace grate 100 from the retail shelf to their car and then into their home.

As another advantage, the top and bottom surfaces of the box 108 provide sufficient surface area for product information and marketing materials, such as a brand name and/or artwork that the retailer may want to include. For example, the retailer may want the box 108 to include a brand name to improve brand awareness. As another example, the retailer may want the box to include artwork to inform potential users of the utility of the fireplace 100 or to increase the attractiveness of the box 108 to attract more customer interest.

It will be understood that while the box 108 is illustrated in a manner whereby the height of the side of the box is reduced, the box could just as easily be positioned in manner whereby the smaller dimension is the width of a top surface rather than a height of the side of the box. Regardless of how the box might be arranged on a shelf, one dimension will be significantly space-saving.

FIG. 3 is a partial perspective view of the fireplace grate showing an assembly procedure and FIG. 4 is a partial cross section view of the fireplace grate showing details of a connection point. As can be seen in FIG. 3, one of the cross bars 102 is positioned over one of the support bars 104 so that corresponding apertures in the cross bar 102 and support bar 104 are aligned. In the embodiment shown, the aperture in the support bar 104 is internally threaded. The user inserts the threaded fastener 106 through the aperture in the cross bar 102 and rotates the fastener 106 in a clockwise direction with the tool 110 to engage the threads in the hole in the support bar. In this manner, the cross bar 102 is securely fastened to the support bar 104. The procedure is repeated, with each cross bar 102 spanning between two support bars 104. In the embodiment shown, each cross bar 102 may be evenly spaced from one another.

As can be seen in FIG. 4, the aperture in the cross bar 102 that receives the fastener 106 may be countersunk to mate with the tapered head of the fastener to provide a clean appearance to the assembled fireplace grate 100. As described and illustrated herein, the fireplace grate 100 is easy to assemble by the user in just a few minutes and no additional hardware is required.

FIG. 5 illustrates example alternate embodiments 100A, 100B and 100C of the fireplace grate 100. For example, the fireplace grate may be 18 inches long, with four cross bars. As another example, the fireplace grate may be 23 inches long, with five cross bars. As another example, the fireplace grate may be 27 inches long, with five cross bars. Other sizes are contemplated as within the scope of the invention. Other numbers of cross bars and support bars are contemplated as within the scope of the invention. Regardless of the number of cross bars, a disassembled configuration of the fireplace grate can be packaged in the nested, space-saving manner shown in FIG. 2.

In a further embodiment of the fireplace grate 100, the support bars 104 and cross bars 102 are arranged relative to one another in a manner whereby the cross bars are less likely to move together away from a perpendicular and towards a parallel position relative to the support bars. This “collapsing” motion in which the crossbars pivot about the apertures of the support bars is especially likely if the parallel support bars are inadvertently moved in opposing directions.

FIGS. 6-9 illustrate an alternative embodiment of a fireplace grate 100. The embodiment differs from the forgoing embodiments in the position of the cross bars 102 relative to the support bars 104 and relative to each other and the differences are best appreciated by referring to all of the Figures. As shown, each cross bar 102 is mounted in a non-perpendicular manner relative to the support bars 104. In addition, the cross bars 102 are not parallel to each other. To accommodate this design, the support bars 104S and 104L are a different length as are some of the cross bars (102A, 102B in FIGS. 8, 9). The result is a “splayed” effect best appreciated with reference to FIG. 8 and illustrated by a comparison of D1 and D2 where distance D1 taken at a point closest to support bar 104S is smaller than distance D2 taken at a point closest to support bar 104L. By mounting the cross bars 102A, 102B in a manner whereby they are not perpendicular to the support bars 104S, 104L and not parallel to each other, the collapsing problem described above is largely overcome as the cross bars are less likely to pivot about their connection and move in unison towards a collapsed position.

It is noted that the embodiment illustrated in FIGS. 6-9 include four cross bars 102, although other numbers of cross bars 102 may be used, such as three, four, five, six or more cross bars 102. It will be appreciated that an odd number of cross bars 102, such as five cross bars 102 could be used. In such a case that an odd number of cross bars 102 is used, a center one of the cross bars 102 may be perpendicular to the support bars 104S, 104L, even though the overall non-parallel, splayed arrangement is maintained with respect to of the cross bars 102 relative to each other.

While the embodiment shown illustrates a spayed method of mounting cross bars 102 on support bars 104, it will be understood that the cross bars may be mounted in a variety of ways so long as they are not parallel to each other. In the embodiment shown, no two cross bars are parallel to one another. However, the collapsing effect can be reduced or avoided by mounting even a single cross bar in non-parallel relationship to the other cross bars.

In the embodiment shown in FIGS. 6-9, the support bars 104 are each equipped with a support leg 115 attached to the underside of each bar and constructed and arranged to support the grate, especially when loaded with heavy material. In the example embodiment, the support legs 115 are integrally formed on the underside of the support bars but they could also be attached with fasteners, providing optional support to the grate. Although the support legs 115 are shown in connection with the embodiment shown in FIGS. 609, it will be appreciated that support legs 115 may be used in connection with any of the embodiments disclosed herein, including the embodiments disclosed in FIGS. 1-5 and the corresponding descriptions.

FIG. 10 is a perspective view of the fireplace grate of FIGS. 6-9 in a packaged and disassembled configuration. As with the packaging arrangement of the embodiment of FIG. 1, the fireplace grate 100, even with the addition of the support legs 115 and with the cross bars 102A, 102B and support bars 104S, 104L of varying lengths, can be packaged in a nested arrangement that greatly minimizes at least one dimension of the box containing the components.

Claims

1. A fireplace grate comprising:

a plurality of cross bars,

a plurality of support bars, and

a plurality of fasteners, wherein:

each fastener is configured to extend through a hole in one of the cross bars and engage a corresponding threaded hole in one of the support bars so that each cross bar can be fastened to the plurality of support bars in an assembled configuration with each cross bar spanning the plurality of support bars, and

in a disassembled configuration, a width of the fireplace grate is less than 50% of a width of the fireplace grate in the assembled configuration.

2. The fireplace grate of claim 1, wherein in the disassembled configuration, the cross bars and support bars are in a nested relationship to each other.

3. The fireplace grate according to claim 1, wherein a height of the fireplace grate in the disassembled configuration is less than 50% of a height of the fireplace grate in the assembled configuration.

4. The fireplace grate according to claim 2, wherein the height of the fireplace grate in the disassembled configuration is less than 33% of the height of the fireplace grate in the assembled configuration.

5. A method of providing a fireplace grate, the method comprising the steps of:

arranging, in a box, a plurality of cross bars, a plurality of support bars and a plurality of fasteners, wherein the plurality of support bars and the plurality of cross bars are in a nested arrangement in the box in a disassembled configuration, wherein:

each fastener is configured to extend through a hole in one of the cross bars and engage a corresponding threaded hole in one of the support bars so that each cross bar can be fastened to the plurality of support bars in an assembled configuration with each cross bar spanning the plurality of support bars, and

a width of the fireplace grate in the disassembled configuration is less than 50% of a width of the fireplace grate in the assembled configuration.

6. The method according to claim 4, wherein a height of the fireplace grate in the disassembled configuration is less than 50% of a height of the fireplace grate in the assembled configuration.

7. The method according to claim 5, wherein the height of the fireplace grate in the disassembled configuration is less than 33% of the height of the fireplace grate in the assembled configuration.

8. A fireplace grate comprising:

a plurality of cross bars,

a plurality of support bars, and

a plurality of fasteners, wherein: each fastener is configured to extend through an aperture in one of the cross bars and engage a corresponding threaded aperture in one of the support bars so that each cross bar can be fastened to the plurality of support bars in an assembled configuration with each cross bar spanning the plurality of support bars, and wherein: at least one of the cross bars is mounted in a manner whereby it is not substantially perpendicular to the other cross bars.

9. The fireplace grate of claim 8, wherein at least one of the cross bars is mounted in a manner whereby it is not perpendicular to the support bars.

10. The fireplace grate of claim 8, wherein the cross bars are arranged in a splayed manner relative to the support bars.

11. The fireplace grate of claim 8, wherein a distance D1 between each cross bar at a first side of the grate is smaller than distance D2 at an opposite side of the grate.

12. The fireplace grate of claim 11, wherein a first support bar at a first end of the grate is longer than a second support bar at a second end of the grate.

13. The fireplace great of claim 8, further including at least one support leg mounted on an underside of at least one support bar.

14. A method of assembling a fireplace grate comprising:

providing a plurality of cross bars, a plurality of support bars, and

a plurality of fasteners;

extending each fastener through a hole in one of the cross bars to engage a corresponding threaded hole in one of the support bars, thereby fastening each cross bar to the plurality of support bars in an assembled configuration with each cross bar spanning the plurality of support bars.

15. The method of claim 14, further including removing the cross bars, plurality of support bars, and plurality of fasteners from a nested relationship in a box.