Modular gas fireplace insert

• US 6,029,655 A
• Filed: 06/15/1998
• Issued: 02/29/2000
• Est. Priority Date: 04/27/1998
• Status: Expired due to Term

• Current Assignee: Hussong Manufacturing Company, Inc.
• Original Assignee: Hussong Manufacturing Company, Inc.
• Inventors: Hussong, Dudley D., Reimers, David S.
• Primary Examiner(s): Lazarus, Ira S.
• Assistant Examiner(s): CLARKE, SARA SACHIE
• Application Number:
  US09/097,422
• Time in Patent Office: 624 Days
• Field of Search: 126/77, 126/80, 126/85 B, 126/312, 126/317, 126/515, 126/516, 126/524, 126/525, 126/527, 126/512, 126/531
• US Class Current: 126/515
• CPC Class Codes: F23J 13/025 composed of concentric elements, e.g. double walled terminals for balanced flue arrangements F23L17/04
• CPC Class Codes: F24B 1/1808 Simulated fireplaces
• CPC Class Codes: F24C 3/004 of the closed type

Abstract

A gas fireplace insert for inserting into existing solid fuel fireplaces is made into modules that are separable for installation and can be later assembled together. A housing module which includes a combustion chamber supports a separable module comprising a duct for fresh air intake. The duct includes a connection collar for an air intake pipe leading to the interior of the duct. The duct also has a pass through collar for carrying exhaust gases from the fireplace. The collars can be attached to an exhaust pipe and air intake pipe respective, which extend through the existing chimney. The duct module is separated from the housing module for installation so that the pipe connections are easier to make with the lighter, smaller module. Once the pipes are connected to the respective collars, the gas fireplace housing module is inserted into the existing fireplace opening and the air intake duct module is attached to the fireplace housing with openings in the housing aligning with and can be sealed relative to the exhaust pipe connection collar and with the opening in the air intake duct.

Claims

1. A module gas fireplace insert for inserting into an existing solid fuel burning fireplace having an existing solid fuel burning fireplace chimney comprising a housing for forming a combustion chamber having walls including a rear wall and an upper wall, the rear wall having an air inlet opening therein and the upper wall having an exhaust outlet opening therein;

an intake air duct module, the duct module including a first duct section extending along the rear wall and a unitary second duct section extending along the upper wall, the first and second sections of the duct module having an internal duct passageway, an air outlet opening in the first section of the duct module that aligns the air inlet opening in the rear wall of the housing, and including a connecting sleeve fixedly mounted on a top wall of the second duct section for a fresh air intake open to the duct passageway, and an exhaust connector sleeve fixedly mounted on the second duct section of the duct module and passing through the duct passageway, the exhaust connector sleeve aligning with the exhaust outlet opening in the upper wall of the housing, the duct module, including the connecting sleeve and the exhaust connector sleeve, being removable as a unit from the housing, connecting to mounted to extend through the existing solid fuel fireplace chimney into the existing solid fuel fireplace and connected to the connection sleeve and exhaust connector sleeve, respectively, with the duct module removed from the housing, and the duct module and connected fresh air and exhaust pipes being attached to the housing while the housing is in the solid fuel burning fireplace.

2. The fireplace insert of claim 1 and a gasket between the duct module and the upper housing wall to surround the exhaust opening in the upper wall of the housing.

3. The fireplace insert of claim 2 and a gasket between the duct module and the rear wall of the housing for sealing around the intake air opening.

4. The fireplace insert of claim 1, wherein the duct module includes wall portions forming a heated air passageway in combination with the housing when installed thereon.

5. The fireplace insert of claim 1 including a termination assembly for supporting both the fresh air and duct pipes on an upper end portion of existing solid fuel fireplace chimney including a flange supportable on an upper edge of the chimney, and the termination assembly having air intake and heated exhaust gas passageways communicating with the atmosphere.

6. A method of installing a gas fireplace insert in an existing solid fuel burning fireplace opening having an existing solid fuel burning fireplace chimney, wherein the insert has at least two modules including an intake air duct module and a burner housing module, including providing an exhaust opening from the burner housing in a first wall and a fresh air intake opening into the combustion chamber in a second wall and separated from the exhaust opening, securing two separate pipes to the existing chimney at an upper end of the existing and extending the separate pipes into the existing fireplace opening, placing the intake air duct module in the existing fireplace opening when separated from the housing, connecting the pipes to separate couplers mounted on the intake air duct module while the intake air duct module is separated from the burner housing module and inside the existing fireplace opening, installing the burner housing module into the existing fireplace opening, positioning the air intake duct module on the burner housing module inside the existing fireplace opening with one coupler aligning with and sealed relative to a perimeter of the exhaust opening in the burner housing module, the intake air duct module having an opening positioned to align with the intake air opening in the housing, and securing the intake air duct module to the burner housing module while inside the existing fireplace opening.

7. The method of claim 6, including the step of providing a gasket surrounding the intake air opening and the opening in the air intake air duct.

8. The method of claim 6 including the step of supporting the separate pipes on a termination assembly at first ends, and wherein the securing step comprises supporting the termination assembly on the top of an existing chimney.

9. The method of claim 6 including the step of applying a sealant between the pipes and the couplers when connecting the pipes to the couplers.

10. The method of claim 6 including placing the pipes concentrically one inside the other.

11. The method of claim 6 including the step of placing the pipes side by side.

12. The method of claim 6 including the step of providing flexible pipes which are linearly extendable to increase their lengths.