CA3006731A1 - Emberbed assembly for use in electric fireplace - Google Patents

Abstract

An electric fireplace that is configured to look more realistic, i.e. more like a traditional wood-burning fireplace, includes a grate and an emberbed. The grate has a substantially horizontally-oriented middle section. The emberbed is positioned substantially directly below the middle section of the grate. Additionally, the emberbed is positioned spaced apart from the grate by a bed gap. The bed gap can be between approximately one-half inch and four inches. Additionally, the emberbed can be selectively coupled to the grate.

Description

EMBERBED ASSEMBLY FOR USE IN ELECTRIC FIREPLACE
RELATED APPLICATION
[0001]
The application claims priority on U.S. Provisional Application Serial No.
62/513,166 filed on May 31, 2017, entitled "EMBERBED ASSEMBLY FOR USE IN
ELECTRIC FIREPLACE". As far as is permitted, the contents of U.S. Provisional Application Serial No. 62/513,166 are incorporated in their entirety herein by reference.
BACKGROUND

[0002]
Fireplaces of various types can be installed in homes and commercial establishments as a means to provide a source of heat and for aesthetic reasons.
Although traditionally such fireplaces have most often taken the form of wood-burning fireplaces and gas-burning fireplaces, electric fireplaces have become increasingly popular in recent years. An electric fireplace is typically designed to look like a traditional wood-burning fireplace, but does not actually burn wood. As such, there is a continuing desire to make electric fireplaces look more realistic, i.e. to make electric fireplaces look more like a traditional wood-burning fireplace.
SUMMARY

[0003]
The present invention is directed toward an electric fireplace that is configured to look more realistic, i.e. more like a traditional wood-burning fireplace.
In various embodiments, the electric fireplace includes a grate and an emberbed.
The grate has a substantially horizontally-oriented middle section. The emberbed is positioned substantially directly below the middle section of the grate.
Additionally, the emberbed is positioned spaced apart from the grate by a bed gap.

[0004] In some embodiments, the bed gap is between approximately one-half inch and four inches. Additionally, the emberbed can be selectively coupled to the grate.

[0005]
The electric fireplace can also include an assembly base that is formed together with the emberbed as a unitary structure. The unitary structure of the emberbed and the assembly base can then be selectively coupled to the grate.
In some such embodiments, the assembly base provides a flat surface that extends laterally (e.g., to the left and to the right) away from the emberbed.

[0006] In certain embodiments, the electric fireplace can further include an assembly light source that is positioned directly underneath the emberbed. The assembly light source can be selectively activated to create a glowing effect for the emberbed. In some such embodiments, the assembly light source includes a plurality of LED light bulbs.

[0007]
The components of the electric fireplace can be formed from any suitable materials.
For example, in some non-exclusive alternative embodiments, the emberbed can be formed from at least one of vacuum-molded plastic, pour-molded resin, injected plastic or paper pulp. Additionally, in certain non-exclusive embodiments, the grate can be formed from metallic materials. Alternatively, the emberbed and/or the grate can be formed from other suitable materials. For example, in other embodiments, the grate can be formed from plastic, resin, and/or another suitable material.

[0008]
Additionally, in some embodiments, the electric fireplace can further include at least one simulated log that is positioned on top of the grate. The at least one simulated log can be formed from a molded resin material. Alternatively, one or more of the logs can be made of other materials, including, but not limited to, vacuum molded plastic, pour-molded resin, injected plastic or paper pulp.

[0009]
The electric fireplace can further include a fireplace housing, wherein the grate and the emberbed are positioned substantially within the fireplace housing.

[0010] In another embodiment, the present invention is further directed toward a grate and an emberbed assembly that is selectively coupled to the grate.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The novel features of this invention, as well as the invention itself, both as to its structure and its operation, will be best understood from the accompanying drawings, taken in conjunction with the accompanying description, in which similar reference characters refer to similar parts, and in which:

[0012] Figure 1 is a front perspective view of an embodiment of an electric fireplace having features of the present invention;

[0013] Figure 2A is a front perspective view of a portion of another embodiment of the electric fireplace;

[0014] Figure 2B is a partial cutaway view of the portion of the electric fireplace taken on line B-B in Figure 2A; and

[0015] Figure 2C is an exploded partial cutaway view of the portion of the electric fireplace illustrated in Figure 2B.
DESCRIPTION

[0016] Embodiments of the present invention are described herein in the context of an emberbed assembly for use in an electric fireplace. More specifically, as provided herein, the emberbed assembly is configured to give the electric fireplace a more realistic looking appearance, i.e. more like a traditional wood-burning fireplace, in comparison to conventional electric fireplaces.

[0017] Those of ordinary skill in the art will realize that the following detailed description of the present invention is illustrative only and is not intended to be in any way limiting. Other embodiments of the present invention will readily suggest themselves to such skilled persons having the benefit of this disclosure.
Reference will now be made in detail to implementations of the present invention as illustrated in the accompanying drawings.

[0018] In the interest of clarity, not all of the routine features of the implementations described herein are shown and described. It will, of course, be appreciated that in the development of any such actual implementation, numerous implementation-specific decisions must be made in order to achieve the developer's specific goals, such as compliance with application-related and business-related constraints, and that these specific goals will vary from one implementation to another and from one developer to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking of engineering for those of ordinary skill in the art having the benefit of this disclosure.

[0019]
Figure 1 is a front perspective view of an embodiment of an electric fireplace 10 having features of the present invention. As illustrated herein, the electric fireplace 10 can be used to provide heat and to simulate a wood-burning fire, e.g., in a room of a home or other type of building. More particularly, in certain embodiments, the electric fireplace 10 can be configured to look like a traditional wood-burning fireplace, although the electric fireplace 10 does not actually burn wood.

[0020] The design of the electric fireplace 10 can be varied. In certain embodiments, as illustrated in Figure 1, the electric fireplace 10 can include a fireplace housing 12, a viewing area 14 within the fireplace housing 12, a simulated flame 16 (i.e. when the electric fireplace 14 is in use), one or more simulated logs 18, a first light source 20 (illustrated in phantom) that can be used to selectively generate the simulated flame 16 and create a glowing effect for the simulated logs 20, a grate 22, a heater 24, a controller 26, and an emberbed assembly 28. Alternatively, the electric fireplace 10 can include more components or fewer components than those specifically illustrated in Figure 1. For example, in one non-exclusive alternative embodiment, the electric fireplace 10 can be designed without the heater 24.

[0021] As an overview, in certain embodiments, the electric fireplace 10 is uniquely configured to provide a more realistic appearance for the electric fireplace 10, i.e. more like a traditional wood-burning fireplace.
More particularly, the emberbed assembly 28, as illustrated and described herein, is configured to look more realistic as it has a smaller and lower profile than in existing electric fireplaces and is positioned substantially directly below at least a portion of the grate

22 and is spaced apart a bed gap 30 from the main substantially horizontally-oriented middle section 22B of the grate 22. Additionally, in various embodiments, the emberbed assembly 28 includes an emberbed 32 and an assembly base 34 that are formed together as a unitary structure, and an assembly light source 236 (illustrated in Figure 2B) that can be used to create a glowing effect for the emberbed 32.
[0022] The fireplace housing 12 can be sized and shaped to retain most, if not all, of the remaining components of the electric fireplace 10. In particular, in many embodiments, the simulated flame 16 (i.e. when the electric fireplace 10 is in use), the one or more simulated logs 18, the first light source 20, the grate 22, the heater 24, the controller 26 and the emberbed assembly 28 can be positioned substantially within the fireplace housing 12. In some embodiments, the fireplace housing 12 has a substantially rectangular shape, and includes a housing base 38 that supports various components of the electric fireplace 10. Additionally, the fireplace housing 12 can further include a window (not shown) located at a front side of the fireplace housing 12. The window can include tempered glass or a meshed door through which the simulated flame 16 can be seen. Alternatively, the fireplace housing can have a different shape and/or the fireplace housing 12 can be designed without the window.

[0023] Further, the fireplace housing 12 can be formed from any suitable materials. For example, in various embodiments, the fireplace housing 12 can be formed from any of a number of suitable metallic materials.

[0024] The viewing area 14 is the area within the fireplace housing 12 in which the simulated flame 16, the simulated logs 18, the grate 22 and the emberbed assembly 28 are displayed and can be seen by the user.

[0025] The simulated flame 16 can be formed from any suitable method. For example, in various embodiments, the electric fireplace 10 can utilize the first light source 20 to illuminate a reflective medium (not shown), e.g., a suitable metal material, to generate the simulated flame 16, i.e. a flickering flame image.
The first light source 20 can have any suitable design. For example, in one non-exclusive alternative embodiment, the first light source 20 can include an LED panel having one or more LED light bulbs. Alternatively, the first light source 20 can include other types of light bulbs or another type of light source. As noted and as shown in Figure 1, in various embodiments, the simulated flame 16, when in use, is displayed within the viewing area 14 of the electric fireplace 10.

[0026] Additionally and as noted above, the simulated (or artificial) logs 18 can also be positioned within the viewing area 14. Similar to the simulated flame 16, the simulated logs 18 can utilize the first light source 20 to create a glowing effect for the simulated logs 20. Thus, the combination of the simulated logs 18 and the simulated flame 16 can use the first light source 20 to create the appearance of burning logs, thereby closely simulating the flames of a wood-burning fireplace.
Alternatively, the electric fireplace 10 can include a second light source (not shown) to create the glowing effect for the simulated logs.

[0027] Further, as illustrated, the simulated logs 18 can be placed on top of the grate 22, i.e. an actual or a simulated grate.

[0028] As illustrated, the grate 22 includes a pair of substantially vertically-oriented, spaced apart ends 22A, and a substantially horizontally-oriented middle section 22B that extends between the ends 22A. Additionally, as noted, the grate 22 is configured to support the simulated logs 18 above the housing base 38 and/or the emberbed assembly 28. More particularly, in various embodiments, the simulated logs 18 are supported by the substantially horizontally-oriented middle section 22B of the grate 22.

[0029] As described herein, and as illustrated in Figure 1, the middle section 22B of the grate 22 provides a base supporting structure for the simulated logs 18 that is oriented substantially horizontally. Thus, even in embodiments where the middle section 22B of the grate 22 includes portions that slope generally upwardly, downwardly and/or at an angle away from the substantially horizontal base supporting structure of the middle section 22B, the middle section 22B can still be said to be substantially horizontally oriented.

[0030] Further, the heater 24, e.g., an integrated electric heater, can be configured to provide heated air which can be directed in a generally outward direction away from the electric fireplace 10.
More particularly, in certain embodiments, the heater 24 can include a blower (not shown) that blows hot air through heat vents 40 into the area surrounding the electric fireplace 10, e.g., a room in a house, in order to heat such area. In some such embodiments, the heat vents 40 can be positioned at or near an upper portion of the fireplace housing 12.

[0031]
The controller 26 can include one or more circuits or processors that can be utilized to control the various functions of the electric fireplace 10. For example, the controller 26 can be utilized to activate and/or control (i) the intensity of the first light source 20 within the electric fireplace 10 that generates the simulated flame 16 and creates the glowing effect for the simulated logs 18, (ii) the speed of the blower within the heater 24 to regulate the amount of heat produced and dispersed by the heater 24, and (iii) the intensity of the assembly light source 236 that creates the glowing effect for the emberbed 32.

[0032]
The emberbed assembly 28, e.g., formed at least in part by the emberbed 32 and/or the assembly base 34, is positioned adjacent to the housing base 38 and substantially below the grate 22, e.g., substantially directly below the middle section 22B of the grate 22. However, as utilized herein, the emberbed assembly 28 being positioned substantially directly below the grate 22 allows for some of the emberbed 32 and/or the assembly base 34 to extend outwardly enough that they are not positioned directly below the grate 22. Additionally, as provided herein, in certain embodiments, the emberbed assembly 28 is configured to be selectively coupled to the grate 22. In existing electric fireplaces, the emberbed is typically formed together with the grate as a unitary structure. However, in the present invention, the emberbed 32 (and the assembly base 34) is formed separate from the grate 22, and, as noted, can be selectively coupled to the grate 22.
With such design, the emberbed 32 can have a smaller and lower profile that enables the bed gap 30, and thus provides a more realistic appearance for the emberbed 32, and thus for the electric fireplace 10.

[0033]
Further, as noted above, the emberbed 32 is spaced apart the bed gap 30 from the substantially horizontally-oriented middle section 22B of the grate 22 (i.e.

ignoring the ends 22A of the grate 22 that curve downward and provide support for the rest of the grate 22). It should be appreciated that due to the various bumps, curves and undulations formed in the emberbed 32 that the size of the bed gap will vary across the surface of the emberbed 32. Thus, as utilized herein, the bed gap 30 can be defined as the minimum distance between an upper surface 32A of the emberbed 32 and the substantially horizontally-oriented middle section of the grate 22, i.e. as measured in a generally vertical direction.

[0034] As provided herein, the size of the bed gap 30 can be varied. For example, in certain non-exclusive alternative embodiments, the size of the bed gap 30 can be between approximately one-half inch and four inches. Alternatively, in other embodiments, the size of the bed gap 30 can be greater than four inches or less than one-half inch. As other, non-exclusive examples, the bed gap 30 can be between approximately one-quarter inch and six inches. Stated is a different fashion, in alternative non-exclusive embodiments, the bed gap 30 can be at least one-eight (1/8), one-quarter (1/4), one-half (1/2), three-quarters (3/4), one, two, three, four, five, or six inches.

[0035] Still alternatively, in one embodiment, the electric fireplace 10 can be designed without an actual bed gap, but with a mere illusion of a bed gap between the emberbed 32 and the middle section 22B of the grate 22.

[0036] Figure 2A is a front perspective view of a portion of another embodiment of the electric fireplace 210. As shown, the electric fireplace illustrated in Figure 2A is substantially similar to the electric fireplace 10 illustrated and described above in relation to Figure 1, e.g., with only the simulated logs 218 having a slightly different appearance than what is shown in Figure 1. In particular, Figure 2A again provides a perspective view of the simulated logs 218, the grate 222 and the emberbed assembly 228 of the electric fireplace 210.

[0037] Figure 2A further illustrates a slightly different perspective of the bed gap 230 that is formed between the upper surface 232A of the emberbed 232 and the main substantially horizontally-oriented middle section 222B of the grate 222.

[0038] Figure 2B is a partial cutaway view of the portion of the electric fireplace taken on line B-B in Figure 2A. As shown, Figure 2B again illustrates the simulated logs 218, the grate 222 and the emberbed assembly 228, i.e. the emberbed 232 and the assembly base 234. Additionally, Figure 2B also illustrates the assembly light source 236 that can be utilized, i.e. selectively activated, for purposes of creating a glowing effect for the emberbed 232. Figure 2B also illustrates another view of the bed gap 230 between the emberbed 232 and the middle section 222B of the grate 222.

[0039] The simulated logs 218 can be formed from any suitable materials.
For example, in certain non-exclusive alternative embodiments, the simulated logs can be hollow molded logs that are formed from a molded resin material.
Alternatively, the simulated logs 218 can be formed from another suitable material.

[0040] Additionally, the grate 222 can also be formed from any suitable materials. For example, in certain non-exclusive alternative embodiments, the grate 222 can be formed from metallic materials such as a welded steel or aluminum material. Alternatively, the grate 222 can be formed from plastic, resin, and/or another suitable material.

[0041] Further, the emberbed assembly 228, i.e. the emberbed 232 and the assembly base 234, can also be formed from any suitable materials. For example, in some embodiments, the emberbed assembly 228 can be formed from vacuum-molded plastic, pour-molded resin, injected plastic or paper pulp.
Alternatively, the emberbed assembly 228 can be formed from other suitable materials.

[0042] Still further, in alternative embodiments, the emberbed 232 can be formed separately from the grate 222, or the emberbed 232 can be integrally formed with the grate 222 as a unitary structure.

[0043] Additionally, the assembly light source 236 can have any suitable design.
For example, as illustrated, the assembly light source 236 can include a flat, PCB
board 236A upon which are mounted a plurality of LED light bulbs 236B.
Additionally, as shown, the assembly light source 236 can be positioned substantially below, e.g., substantially directly below, the emberbed 232. With such design, the assembly light source 236 can have a low profile that can fit easily underneath the emberbed 232 in order to create the glowing effect for the emberbed 232.
Alternatively, the assembly light source 236 can have another suitable design and/or use a different type of light bulbs. Still alternatively, the assembly light source 236 can be positioned in another manner relative to the emberbed 232, i.e. not substantially directly below the emberbed 232.

[0044] The location and size of the PCB board 236A can be varied. For example, in some embodiments, the PCB board 236A can be substantially rectangle-shaped, with an upper surface 236C upon which the plurality of LED light bulbs are secured or mounted. Alternatively, the PCB board 236A can have another suitable shape.

[0045] Additionally, the quantity, size, type and placement of the LED
light bulbs 236B can also be varied. For example, in some embodiments, the assembly light source 236 can include twenty LED light bulbs 236B. Alternatively, the assembly light source 236 can include greater than twenty or fewer than twenty LED
light bulbs 236B.

[0046] It should be appreciated that the low profile for the assembly light source 236 enables the emberbed assembly 228 as a whole to have a smaller and lower profile such that it can fit substantially below the grate 222 and be spaced apart from the grate 222, i.e. the middle section 222B of the grate 222, by the bed gap 230. As noted, the low profile for the emberbed assembly 228, i.e. the emberbed 232, enables the electric fireplace 210 to have a more realistic appearance.

[0047] It should further be appreciated that the use of LED light bulbs make it generally unnecessary to access the assembly light source 236 as the LED
light bulbs have a very long life span and do not need to be regularly replaced.

[0048] Figure 2C is an exploded partial cutaway view of the portion of the electric fireplace 210 illustrated in Figure 2A. In particular, Figure 20 again illustrates the simulated logs 218, the grate 222 and the emberbed assembly 228, i.e. the emberbed 232, the assembly base 234 and the assembly light source 236.
Additionally, Figure 2C also illustrates that the electric fireplace 210 can further include at least one first fastener 242 (two are illustrated in Figure 2C) that can be =
utilized to fasten the simulated logs 218 to the grate 222; and at least one second fastener 244 (two are illustrated in Figure 2C) that can be utilized to fasten the grate 222 to the emberbed assembly 228, i.e. to the emberbed 232 and/or the assembly base 234.

[0049] The first fasteners 242 can have any suitable design. For example, as shown in the embodiment illustrated in Figure 2C, the first fasteners 242 can be screws that extend through the grate 222 and into and/or through at least a portion of the simulated logs 218. Alternatively, the first fasteners 242 can have another suitable design. Still alternatively, the simulated logs 218 can be selectively coupled to the grate 222 in another suitable manner.

[0050] Somewhat similarly, the second fasteners 244 can have any suitable design. For example, in the embodiment shown in Figure 2C, the second fasteners 244 can be screws that extend through the emberbed assembly 228, i.e. the emberbed 232 and/or the assembly base 234, and into the grate 222.
Alternatively, the second fasteners 244 can have another suitable design. Still alternatively, the emberbed assembly 228 can be selectively coupled to the grate 222 in another suitable manner.

[0051] It should be understood that the use of the terms "first fasteners" and "second fasteners" is merely for convenience and ease of discussion; and either fasteners 242, 244 can be referred to as the "first fasteners" and/or the "second fasteners".

[0052] As noted above, the emberbed 232 and the assembly base 234 can be formed together as a unitary structure. With such design, as shown in Figure (also shown in Figure 2B), the assembly base 234 can provide a flat surface (i.e. a "flat floor") that extends laterally away, i.e. outwardly to the left and the right, from the emberbed 232. Alternatively, the emberbed 232 and the assembly base 234 can be formed separately from one another, and can be selectively coupled to one another in any suitable manner.

[0053] Importantly, as provided herein, the emberbed assembly 228, e.g., the emberbed 232, is formed separately from the grate 222, and is then selectively coupled to the grate 222. With such design, the emberbed assembly 228, e.g., the emberbed 232, can have a much smaller and lower profile than in existing electric fireplaces. This enables the presence of the bed gap 230 (illustrated, for example, in Figure 2A), and, thus, the ability to create a more realistic appearance for the electric fireplace 210, i.e. more like a traditional wood-burning fireplace.

[0054] It is understood that although a number of different embodiments of the emberbed assembly 28 for the electric fireplace 10 have been illustrated and described herein, one or more features of any one embodiment can be combined with one or more features of one or more of the other embodiments, provided that such combination satisfies the intent of the present invention.

[0055] While a number of exemplary aspects and embodiments of an emberbed assembly 28 for an electric fireplace 10 have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions and sub-combinations as are within their true spirit and scope.

Claims (25)

CLAIMS:

1. An electric fireplace comprising:
a grate having a substantially horizontally-oriented middle section; and an emberbed that is positioned substantially directly below the middle section of the grate, the emberbed being positioned spaced apart from the grate by a bed gap.

2. The electric fireplace of claim 1 wherein the bed gap is between approximately one-half inch and four inches.

3. The electric fireplace of claim 3 wherein the emberbed is selectively coupled to the grate.

4. The electric fireplace of claim 1 further comprising an assembly base that is formed together with the emberbed as a unitary structure.

5. The electric fireplace of claim 4 wherein the emberbed and the assembly base are selectively coupled to the grate.

6. The electric fireplace of claim 4 wherein the assembly base provides a flat surface that extends laterally away from the emberbed.

7. The electric fireplace of claim 1 further comprising an assembly light source that is positioned directly underneath the emberbed, the assembly light source being selectively activated to create a glowing effect for the emberbed.

8. The electric fireplace of claim 7 wherein the assembly light source includes a plurality of LED light bulbs.

9. The electric fireplace of claim 1 wherein the emberbed is formed from at least one of vacuum-molded plastic, pour-molded resin, injected plastic or paper pulp.

10. The electric fireplace of claim 1 wherein the emberbed is formed from vacuum-molded plastic.

11. The electric fireplace of claim 1 wherein the grate is formed from metallic materials.

12. The electric fireplace of claim 1 further comprising at least one simulated log that is positioned on top of the grate.

13. The electric fireplace of claim 12 wherein the at least one simulated log is formed from a molded resin material.

14. The electric fireplace of claim 1 further comprising a fireplace housing, wherein the grate and the emberbed are positioned substantially within the fireplace housing.

15. An electric fireplace comprising:
a grate; and an emberbed assembly that is selectively coupled to the grate.

16. The electric fireplace of claim 15 wherein the emberbed assembly includes an emberbed and an assembly base that are formed together as a unitary structure.

17. The electric fireplace of claim 15 wherein the grate includes a substantially horizontally-oriented middle section, and wherein the emberbed assembly includes an emberbed that is positioned substantially directly below the middle section of the grate.

18. The electric fireplace of claim 17 wherein the emberbed is spaced apart a bed gap from the middle section of the grate.

19. The electric fireplace of claim 18 herein the bed gap is between approximately one-half inch and four inches.

20. The electric fireplace of claim 17 further comprising an assembly light source that is positioned directly underneath the emberbed, the assembly light source being selectively activated to create a glowing effect for the emberbed.

21. The electric fireplace of claim 20 wherein the assembly light source includes a plurality of LED light bulbs.

22. The electric fireplace of claim 15 wherein the grate is formed from metallic materials, and wherein the emberbed assembly is formed from vacuum-molded plastic.

23. The electric fireplace of claim 15 further comprising at least one simulated log that is positioned on top of the grate.

24. The electric fireplace of claim 23 wherein the at least one simulated log is formed from a molded resin material.

25. The electric fireplace of claim 15 further comprising a fireplace housing, wherein the grate and the emberbed assembly are positioned substantially within the fireplace housing.