Modular fireplace

• US 6,024,085 A
• Filed: 07/23/1998
• Issued: 02/15/2000
• Est. Priority Date: 07/23/1998
• Status: Expired due to Term

• Current Assignee: Deborah Hodge Harrison
• Original Assignee: Hodge, Deborah L., Hodge, James Roe Jr.
• Inventors: Hodge, Deborah L., Hodge, James Roe Jr.
• Primary Examiner(s): DORITY, CARROLL B
• Application Number:
  US09/121,771
• Time in Patent Office: 572 Days
• Field of Search: 126/25 R, 126/9 R, 126/8, 126/500, 110/336, 110/338
• US Class Current: 126/500
• CPC Class Codes: F24B 1/18 Stoves with open fires, e.g. fireplaces

Abstract

The present invention encompasses a modular fireplace having a first side wall, a second side wall, and a back wall that is contiguous with the first side wall and the second side wall and defines an interior open-faced firebox region having a substantially "U" shape in top plan view. The first side wall is constructed from a plurality of sequentially stacked modular first side blocks and the second side wall is formed from a plurality of sequentially stacked modular second side blocks. The back wall has a first modular corner block, a second modular corner block, and at least one substantially vertical spacer block that are joined so that the first corner block and the second corner block are contiguous with the spacer block. To aid in the efficient drafting of the fireplace, each of the spacer blocks may have a spacer block air chamber extending therein from an open upper end on the spacer block top end to a closed lower end proximate the spacer block bottom end. Further, the first corner block may have a first corner block air chamber therein extending from an open first corner block upper end on the first corner block top end to a closed first corner block lower end proximate the first corner block bottom end, and the second corner block may have a second corner block air chamber extending therein from an open second corner block upper end on the second corner block top end to a closed second corner block lower end proximate the second corner block bottom end. The modular sections of the modular fireplace are engaged in a nesting relationship that serves to orient the respective modular sections, to provide structural support to the modular sections and the modular chimney, and to provide a physical obstruction to the passage of flame, hot gases, and smoke through the joints of the modular sections when the sections are physically joined and mortared together.

Claims

1. A fireplace comprising:

a first side wall having a first side wall top surface and a first side wall bottom surface, the first side wall formed of a plurality of sequentially stacked modular side blocks, each side block having a first horizontally extending side block surface, an opposed second horizontally extending side block surface, a side block proximal end, and an opposed block distal end, wherein the side block has a sideblock longitudinal length therebetween the side block proximal end and the side block distal end, and wherein the first side block surface of one modular side block is sized to complementarily engage the second side block surface of the adjacent modular side block;

a second side wall having a second side wall top surface and a second side wall bottom surface, the second side wall formed of a sequentially stacked plurality of the modular side blocks, wherein said first side wall is spaced apart from and opposes said second side wall, and wherein said first side wall and said second side wall have a longitudinal length substantially equal to the longitudinal length of the side block;

a back wall having a back wall top surface and a back wall bottom surface, the backwall having a backwall longitudinal length therebetween the backwall top surface and the backwall bottom surface, the back wall formed of an upright first modular corner block, an upright second modular corner block, and at least one upright spacer block, the first modular corner block having a first corner block proximal surface, and an opposed first corner block distal surface, the second modular corner block having a second corner block proximal surface, and an opposed second corner block distal surface, the spacer block having a spacer block proximal surface, and an opposed spacer block distal surface, wherein each of the first corner block, the second corner block, and the spacer block have a longitudinal length substantially equal to the longitudinal length of the backwall, wherein the first corner block distal surface is sized to complementarily engage the spacer block proximal surface of the spacer block and the second corner block proximal surface is sized to complementarily engage the spacer block distal surface of the spacer block so that the first corner block and the second corner block are contiguous with the spacer block, wherein the first corner block proximal surface is sized to complementarily engage the side block distal end of the side blocks of the first side wall and the second corner block distal surface is sized to complementarily engage the side block distal end of the side blocks of the second side wall so that the back wall is contiguous with the first side wall and the second side wall and defines an interior open-faced firebox region having a substantially "U" shape in top plan view.

2. The fireplace of claim 1, wherein the back wall has a plurality of substantially vertical spacer blocks including a first spacer block and a second spacer block, wherein the spacer block proximal surface of one spacer block is sized to complementarily engage the spacer block distal surface of the adjacent spacer block in the plurality of spacer blocks, and wherein the first corner block distal surface is sized to complementarily engage the spacer block proximal surface of the first spacer block and the second corner block proximal surface is sized to complementarily engage the spacer block distal surface of the second spacer block so that the first corner block and the second corner block are contiguous with the plurality of spacer blocks.

3. The fireplace of claim 2, wherein each of the spacer blocks includes a spacer block top end and an opposed spacer block bottom end and each of the spacer blocks defines a spacer block air chamber extending therein from an open upper end on the spacer block top end, to a closed lower end proximate the spacer block bottom end.

4. The fireplace of claim 3, wherein the first corner block includes a first corner block top end and an opposed first corner block bottom end and the first corner block defines a first corner block air chamber therein extending from an open first corner block upper end on the first corner block top end to a closed first corner block lower end proximate the first corner block bottom end, and wherein the second corner block includes a second corner block top end and an opposed second corner block bottom end and the second corner block defines a second corner block air chamber extending therein from an open second corner block upper end on the second corner block top end to a closed second corner block lower end proximate the second corner block bottom end.

5. The fireplace of claim 4, wherein the first corner block air chamber, the second corner block air chamber, and each spacer block air chamber has a cylindrical cross-section.

6. The fireplace of claim 4, further comprising a base having a base upper surface and an opposed base lower surface, the base upper surface sized to complementarily engage the first side wall bottom surface, the second side wall bottom surface and the rear wall bottom surface.

7. The fireplace of claim 4, wherein the first side block surface of each side block includes a female indentation therein and the second side block surface of each side block includes a male protrusion extending therefrom, wherein the male protrusion is sized to complementarily engage one female indentation therein.

8. The fireplace of claim 7, wherein the side block distal end of each side block has a female block indentation therein and the first corner block proximal surface of the first corner block includes a first corner block male protrusion extending therefrom, the first corner block male protrusion sized to complementarily engage the female block indentation of the side blocks forming the first side wall, and wherein the second corner block distal surface of the second corner block includes a second corner block male protrusion extending therefrom, the second corner block male protrusion sized to complementarily engage the female block indentation of the side blocks forming the second side wall.

9. The fireplace of claim 8, wherein the spacer block proximal surface of each spacer block includes a spacer block male protrusion extending therefrom and the spacer block distal surface of each spacer block include a spacer block female indentation therein, wherein the spacer block male protrusion is sized to complementarily engage one spacer block female indentation so that the spacer blocks can be integrally stacked.

10. The fireplace of claim 9, wherein the first corner block distal surface of the first corner block includes a first corner block spacer male protrusion sized to complementarily engage one spacer block female indentation so that the first corner block and one of the spacer blocks can be integrally stacked, and wherein the second corner block proximal surface includes a second corner block female indentation therein sized to complementarily engage one spacer block male protrusion so that the second corner block and one of the spacer blocks can be integrally fitted.

11. The fireplace of claim 1, further comprising a firebox top having a firebox top lower surface disposed on the first side wall top surface, the second side wall top surface, and the back wall top surface so that the interior firebox region is enclosed.

12. The fireplace of claim 4, further comprising a smoke lip having a smoke lip first end, an opposed smoke lip second end, a smoke lip inner surface, and a smoke lip outer surface, the smoke lip inner surface of the smoke lip first end disposed onto the first side block upper surface, proximal the first side block proximal end, of the first side block on top of the first side wall, the smoke lip inner surface of the smoke lip second end disposed onto the second side block upper surface, proximal the second side block proximal end, of the second side block on top of the second side wall, so that the smoke lip spans the interior of the open-faced firebox region from the first side wall top surface to the second side wall top surface, and so that the smoke lip, the first side wall, the second side wall, and the back wall define a firebox exhaust opening.

13. The fireplace of claim 12, wherein the smoke lip is made of an angled steel having a "L" shaped cross-section.

14. The fireplace of claim 12, further comprising a smoke chamber throat having a smoke chamber throat top surface and an opposed smoke chamber throat bottom surface, the smoke chamber throat defining a throat opening extending therethrough between the smoke chamber throat top surface to the smoke chamber throat bottom surface, the smoke chamber throat bottom surface disposed onto the first side wall top surface of the first side wall, the second side wall top surface of the second side wall, the back wall top surface of the back wall and the smoke lip outer surface of the smoke lip, so that the smoke chamber throat covers the firebox exhaust opening and the throat opening is in fluid communication with the firebox exhaust opening.

15. The fireplace of claim 12, further comprising a smoke chamber having a smoke chamber top surface, a smoke chamber bottom surface, the smoke chamber top surface defining a smoke chamber exhaust opening therethrough, the smoke chamber bottom surface disposed onto the first side wall top surface, the second side wall top surface, the smoke lip, and the back wall top surface and defining an interior smoke chamber region in fluid communication with the smoke chamber exhaust opening and the firebox exhaust opening.

16. The fireplace of claim 15, wherein the interior smoke chamber is in fluid communication with the first corner block air chamber, the second corner block air chamber, and each of the spacer block air chambers.

17. The fireplace of claim 15, wherein the smoke chamber has a first load bearing section having a first proximal edge and a first distal edge, an opposed second load bearing section having a second proximal edge and a second proximal edge, a first inclined section having a first interior surface, and an opposed second inclined section having a second interior surface, wherein the first interior surface is sized to complementarily engage the first proximal edge of the first load bearing section and the second proximal edge of the second load bearing sections, and wherein the second interior surface is sized to complementarily engage the first distal edge of the first load bearing section and the second distal edge of the second load bearing sections, so that the smoke chamber is formed when the first load bearing section, the second load bearing section, the first inclined section and the second inclined are contiguously engaged.

18. The fireplace of claim 15, further comprising a top plate having a top plate upper surface, an opposed top plate lower surface, the top plate defining a top plate bore extending therethrough the top plate between the top plate upper surface and the top plate lower surface, the top plate lower surface disposed onto the smoke chamber top surface so that the top plate bore is in fluid communication with the smoke chamber exhaust opening.

19. The fireplace of claim 18, further comprising a chimney having a first chimney end and a second chimney end, the chimney defining a chimney passage extending therethrough the chimney between the first chimney end and the second chimney end, the first chimney end disposed upon the top plate upper surface so that the chimney passage is in fluid communication with the top plate bore.

20. The fireplace of claim 18, wherein the fireplace is made of a composition of water, crushed pumice, type S mortar and glass fibers.

21. A fireplace comprising:

a first side wall having a first side wall top surface, a first side wall bottom surface, and a first side wall inner surface, the first side wall formed of a plurality of sequentially stacked modular side blocks, each side block having a first horizontally extending side block surface, an opposed second horizontally extending side block surface, a side block proximal end, and an opposed side block distal end, the first side block surface and the second side block surface substantially planer and parallel to each other, each side block defining at least one block bore extending therethrough between the first side block surface to the second side block surface, wherein the first side surface of one modular side block is sized to complementarily engage the second side block surface of the adjacent side block so that the block bore of each side block substantially co-axially aligns with the block bore of the other side blocks in the first side wall to form at least one substantially vertical first air chamber;

a second side wall, having a second side wall top surface, a second side wall bottom, and a second side wall inner surface, the second side wall inner surface facing and spaced apart from the first side wall inner surface, the first side wall and the second side wall defining an interior firebox region having a horizontal longitudinal length, the second side wall formed of a sequentially stacked plurality of the modular side blocks, wherein the block bore of each side block that forms said second side wall substantially co-axially aligns with the block bore of the other side blocks in the second side wall to form at least one substantially vertical second air chamber, and wherein the first wall inner surface and the second wall inner surface have a longitudinal length substantially equal to the longitudinal length of the firebox region.

22. The fireplace of claim 21, wherein each side block defines a plurality of block bores extending therethrough between the first side block surface to the second side block surface, wherein the first side block surface is sized to complementarily engage the second side block bottom surface of the adjacent side block so that the block bores of each side block substantially co-axially aligns with the block bores of the other side blocks in the stacked plurality of modular side blocks to form a plurality of substantially vertical air chambers.

23. The fireplace of claim 22, wherein each block bore is cylindrical in shape.

24. The fireplace of claim 21, further comprising a base having a base upper surface and an opposed base lower surface, the base upper surface is sized to complementarily engage the first side wall bottom surface and the second side wall bottom surface.

25. The fireplace of claim 21, wherein the first side block surface of each side block includes a female indentation therein and the second side block surface of each side block includes a male protrusion extending therefrom, wherein the male protrusion is sized to complementarily engage one female indentation therein.

26. The fireplace construction of claim 21, further comprising a first smoke lip and an opposed second smoke lip, the first smoke lip having a first smoke lip proximal end, an opposed first smoke lip distal end, a first smoke lip inner surface and a first smoke lip outer surface, the first smoke lip inner surface of the first smoke lip proximal end disposed onto the first side block upper surface, proximal the first side block proximal end, of the first side block on top of the first side wall, the first smoke lip inner surface of the first smoke lip distal end is disposed onto the second side block upper surface, proximal the second side block proximal end, of the second side block on top of the second side wall, so that the first smoke lip spans the interior of the firebox region from the first side wall top surface to the second side wall top surface, the second smoke lip having a second smoke lip proximal end, an opposed second smoke lip distal end, a second smoke lip inner surface and a second smoke lip outer surface, the second smoke lip inner surface of the second smoke lip proximal end disposed onto the first side block upper surface, proximal the first side block distal end, of the first side block on top of the first side wall, the second smoke lip inner surface of the second smoke lip distal end is disposed onto the second side block upper surface proximal the second side block distal end, of the second side block on top of the second side wall, so that the second smoke lip spans the interior of the firebox region from the first side wall top surface to the second side wall top surface, and so that the first side wall, the second side wall, the first smoke lip and the second smoke lip define a firebox exhaust opening.

27. The fireplace of claim 25, wherein the first smoke lip and the second smoke lip are made of angled steel with a "L" shaped cross-section.

28. The fireplace of claim 21, further comprising a firebox top having a firebox lower surface disposed on the first side wall top surface, the second side wall top surface, the first smoke lip upper surface and the second smoke lip upper surface so that the interior firebox region is enclosed.

29. The fireplace of claim 26, further comprising a smoke chamber throat having a smoke chamber throat top surface and an opposed smoke chamber throat bottom surface, the smoke chamber throat defining a throat opening extending therethrough between the smoke chamber throat top surface to the smoke chamber throat bottom surface, the smoke chamber throat bottom surface disposed onto the first side wall top surface of the first side wall, the second side wall top surface of the second side wall, the first smoke lip outer surface of the first smoke lip, and the second smoke lip outer surface of the second smoke lip, so that the smoke chamber throat covers the firebox exhaust opening and the throat opening is in fluid communication with the firebox exhaust opening.

30. The fireplace construction of claim 26, further comprising a smoke chamber having a smoke chamber top surface, a smoke chamber bottom surface, the smoke chamber top surface defining a smoke chamber exhaust opening therethrough, the smoke chamber bottom surface disposed onto the first side wall top surface, the second side wall top surface, the first smoke lip upper surface, and the second smoke lip upper surface, the smoke chamber defining an interior smoke chamber region in fluid communication with the firebox exhaust opening, the smoke chamber exhaust opening, the plurality of first air chambers, and the plurality of second air chambers.

31. The fireplace of claim 30, wherein the smoke chamber has a first load bearing section having a first proximal edge and a first distal edge, an opposed second load bearing section having a second proximal edge and a second proximal edge, a first inclined section having a first interior surface, and an opposed second inclined section having a second interior surface, wherein the first interior surface is sized to complementarily engage the first proximal edge of the first load bearing section and the second proximal edge of the second load bearing sections, and wherein the second interior surface is sized to complementarily engage the first distal edge of the first load bearing section and the second distal edge of the second load bearing sections, so that the smoke chamber is formed when the first load bearing section, the second load bearing section, the first inclined section and the second inclined are contiguously engaged.

32. The fireplace of claim 30, further comprising a top plate having a top plate upper surface, an opposed top plate lower surface, the top plate defining a top plate bore extending therethrough the top plate between the top plate upper surface and the top plate lower surface, the top plate lower surface disposed onto the smoke chamber top surface so that the top plate bore is in fluid communication with the smoke chamber exhaust opening.

33. The fireplace of claim 32, further comprising a chimney having a first chimney end, a second chimney end and defining a chimney passage extending therethrough the chimney between the first chimney end and the second chimney end, the first chimney end disposed upon the top plate upper surface so that the chimney passage is in fluid communication with the top plate bore.

34. A fireplace comprising:

a first side wall having a first side wall top surface, a first side wall bottom surface, and a first side wall inner surface, the first side wall formed of a plurality of sequentially stacked modular first side blocks, each first side block having a first side block upper surface, an opposed first side block lower surface, a first side block proximal end, and an opposed first side block distal end, the first side block upper surface and the first side block lower surface substantially planer and parallel to each other, each first side block defining a plurality of first block bores extending therethrough between the first side block upper surface to the first side block lower surface, wherein the first side upper surface is sized to complementarily engage the first side block bottom surface of the adjacent first side block so that the first block bores of each first side block substantially co-axially aligns with the first block bores of the other first side blocks in the first side wall to form a plurality of first air chambers; and

a second side wall, having a second side wall top surface, a second side wall bottom, and a second side wall inner surface, the second side wall inner surface facing and spaced apart from the first side wall inner surface, the first side wall and the second side wall defining an interior firebox region, the second side wall formed of a plurality of sequentially stacked modular second side blocks, each second side block having a second side block upper surface, an opposed second side block lower surface, a second side block proximal end, and an opposed second side block distal end, the second side block upper surface and the second side block lower surface are substantially planer and parallel to each other, each second side block defining a plurality of second block bores extending therethrough between the second side block upper surface to the second side block lower surface, wherein the second side upper surface is sized to complementarily engage the second side block bottom surface of the adjacent second side block so that the second block bores of each second side block substantially co-axially aligns with the second block bores of the other second side blocks in the second side wall to form a plurality of second air chambers;

wherein the fireplace is made of a composition of water, crushed pumice, Class C fly ash calcium aluminate, and glass fibers.

35. A fireplace comprising:

a first side wall having a first side wall top surface, a first side wall bottom surface, and a first side wall inner surface, the first side wall formed of a plurality of sequentially stacked modular first side blocks, each first side block having a first side block upper surface, an opposed first side block lower surface, a first side block proximal end, and an opposed first side block distal end, the first side block upper surface and the first side block lower surface substantially planer and parallel to each other, each first side block defining at least one first block bore extending therethrough between the first side block upper surface to the first side block lower surface, wherein the first side upper surface is sized to complementarily engage the first side block bottom surface of the adjacent first side block so that the first block bore of each first side block substantially co-axially aligns with the first block bore of the other first side blocks in the first side wall to form at least one first air chamber;

a second side wall, having a second side wall top surface, a second side wall bottom, and a second side wall inner surface, the second side wall inner surface facing and spaced apart from the first side wall inner surface, the first side wall and the second side wall defining an interior firebox region, the second side wall formed of a plurality of sequentially stacked modular second side blocks, each second side block having a second side block upper surface, an opposed second side block lower surface, a second side block proximal end, and an opposed second side block distal end, the second side block upper surface and the second side block lower surface are substantially planer and parallel to each other, each second side block defining at least one second block bore extending therethrough between the second side block upper surface to the second side block lower surface, wherein the second side upper surface is sized to complementarily engage the second side block bottom surface of the adjacent second side block so that the second block bore of each second side block substantially co-axially aligns with the second block bore of the other second side blocks in the second side wall to form at least one second air chamber;

a first smoke lip and an opposed second smoke lip, the first smoke lip having a first smoke lip proximal end, an opposed first smoke lip distal end, a first smoke lip inner surface and a first smoke lip outer surface, the first smoke lip inner surface of the first smoke lip proximal end disposed onto the first side block upper surface, proximal the first side block proximal end, of the first side block on top of the first side wall, the first smoke lip inner surface of the first smoke lip distal end is disposed onto the second side block upper surface, proximal the second side block proximal end, of the second side block on top of the second side wall, so that the first smoke lip spans the interior of the firebox region from the first side wall top surface to the second side wall top surface, the second smoke lip having a second smoke lip proximal end, an opposed second smoke lip distal end, a second smoke lip inner surface and a second smoke lip outer surface, the second smoke lip inner surface of the second smoke lip proximal end disposed onto the first side block upper surface, proximal the first side block distal end, of the first side block on top of the first side wall, the second smoke lip inner surface of the second smoke lip distal end is disposed onto the second side block upper surface proximal the second side block distal end, of the second side block on top of the second side wall, so that the second smoke lip spans the interior of the firebox region from the first side wall top surface to the second side wall top surface, and so that the first side wall, the second side wall, the first smoke lip and the second smoke lip define a firebox exhaust opening; and

a smoke chamber having a smoke chamber top surface, a smoke chamber bottom surface, the smoke chamber top surface defining a smoke chamber exhaust opening therethrough, the smoke chamber bottom surface disposed onto the first side wall top surface, the second side wall top surface, the first smoke lip upper surface, and the second smoke lip upper surface, the smoke chamber defining an interior smoke chamber region in fluid communication with the firebox exhaust opening, the smoke chamber exhaust opening, the plurality of first air chambers, and the plurality of second air chambers.