Prefabricated modular, lightweight fireplace

• US 7,140,364 B1
• Filed: 12/29/2004
• Issued: 11/28/2006
• Est. Priority Date: 01/30/2004
• Status: Active Grant

• Current Assignee: Stuart P. Buffington
• Original Assignee: Stuart P. Buffington
• Inventors: Buffington, Stuart P.
• Primary Examiner(s): Price, Carl D.
• Application Number:
  US11/026,818
• Time in Patent Office: 699 Days
• Field of Search: 126/8, 126/512, 126/200, 126/144, 126/145, 126/151, 126544-551, 126/500, 126/144.1, 502/36.3
• US Class Current: 126/500
• CPC Class Codes: F24B 1/18 Stoves with open fires, e.g. fireplaces
• CPC Class Codes: F24B 1/1808 Simulated fireplaces
• CPC Class Codes: F24B 1/191 Component parts; Accessories

Abstract

A lightweight, prefabricated, modular masonry fireplace. The firebox is pre-cast in modular sections of lightweight vermiculate concrete. A kiva-style version of the fireplace features a modular firebox disposed within an outer facade made from a tubular steel frame, covered with metal-mesh stuccoed and plastered to present the aesthetic configuration of a sculpted adobe fireplace. An alternative, but equally desirable Rumford-style version of the fireplace does not require an outer facade, but also is assembled from lightweight modular sections.

The firebox of all embodiments is cast in modular sections. A central body section of the firebox is placed upon a base, and a smoke plenum section is placed upon the central body section. The central body section, and in some embodiments a portion of the smoke plenum section, define and mostly surround the combustion chamber. The central body section may be a single integral pre-cast component, possibly including an arcuate horizontal section, or may include a plurality of pre-cast planar sections interconnected to collectively constitute the central body portion. All modular components are fashioned from lightweight vermiculite concrete; the combustion chamber is lined with split refractory firebrick or suitable cast refractory alternative. The cast smoke chamber plenum section, which may be a single pre-cast component or a plurality of interconnected modular components, stacks upon the central body to provide a transition from the masonry firebox to a double-walled chimney system.

The fireplace can be placed in a room corner or in a chase on a flat wall. It can also be installed over wood floors, or on upper floors, in old or new construction.

Claims

1. A modular fireplace apparatus comprising:

a firebox comprising;

a base;

a central body comprising pre-cast vermiculite concrete disposable upon said base, and comprising an inner body wall defining and partially surrounding a combustion chamber;

a smoke plenum section comprising pre-cast vermiculite concrete, disposable upon said central body, and comprising transition surfaces for directing smoke to a chimney;

a front portion comprising pre-cast vermiculit concrete and defining a box aperture opening into said combustion chamber; and

a facade locatable around said firebox to at least partially surround and enclose said firebox, said facade comprising;

a lightweight frame comprising a plurality of rigid metal tubes, said frame defining a facade aperture; and

a metal mesh fixedly secured to said lightweight frame and said front portion around said box aperture opening, whereby said mesh extends between said frame and said firebox; and

at least one coat of stucco applied to said wire mesh;

wherein said base, central body, and plenum section are modular, said facade aperture is alignable with said box aperture to permit access through said facade into said combustion chamber, and said central body connectable to said base and said smoke chamber connectable to said central body by refractory mortar.

2. The modular fireplace of claim 1 further comprising a flume attachable to said base for drawing air toward said combustion chamber.

3. The modular fireplace of claim 2 wherein said flame comprises a substantially rectangular shape.

4. The modular fireplace of claim 3 wherein a front of said flume is disposed in substantially coplanar registration with a front surface of said front portion.

5. The modular fireplace of claim 1 wherein said central body comprises a single arcuate component.

6. The modular fireplace of claim 1 wherein said central body comprises a plurality of interconnected substantially planar components.

7. The modular fireplace of claim 6 wherein said central body comprises:

a first right side component and a first left side component, said side components disposed upon said base;

a substantially rectangular, lower, first back component disposed upon said base; and

a trapezoidal second, upper, back component disposed upon said first back component.

8. The modular fireplace of claim 7, wherein said smoke plenum section comprises:

a third back component inclined at an angle from vertical and disposed upon said second back component; and

at least two final side components inclined at an angle from vertical and disposed upon respective ones of said first side components.

9. The modular fireplace of claim 1 wherein said smoke plenum section comprises a single pre-cast component comprising:

a substantially planar top; and

a central chimney aperture;

wherein said transition surfaces are defined on the bottom of said single pre-cast component, arrayed around said chimney aperture.

10. The modular fireplace of claim 1 wherein said front portion comprises a single component defining an arched box aperture.

11. The modular fireplace of claim 7 wherein said first side components define horizontal ledges at their front top corners, and said front portion comprises at least one substantially planar front component disposed vertically upon said ledges.

12. A modular fireplace apparatus comprising:

a base;

a central body section comprising pre-cast vermiculite concrete, disposable upon said base, and comprising;

an inner wall defining and partially surrounding a combustion chamber, and

a front portion comprising pre-cast vermiculite concrete and defining a box aperture opening into said combustion chamber;

a smoke plenum section comprising pre-cast vermiculite concrete and disposable upon said central body, and further comprising transition surfaces for directing smoke to a chimney; and

a facade disposable around said base, said central body section and said front portion, said facade comprising a lightweight tubular frame and a mesh;

wherein said mesh is fixedly secured to said frame and also to said front portion around said box aperture opening, whereby said mesh extends between said frame ant said front portion.

13. The modular fireplace of claim 12 wherein said base, central body, smoke plenum, and front portion are modular.

14. The modular fireplace of claim 12 wherein said facade defines therein a facade aperture, said facade aperture alignable with said box aperture to permit access to said combustion chamber through said facade.

15. The modular fireplace of claim 12 wherein said facade comprises a lightweight metal frame, and said mesh comprises a metal.

16. A method for constructing a modular fireplace comprising the steps of:

constructing a firebox comprising the steps of;

providing a base;

disposing a vermiculite concrete central body on the base, the body comprising an inner body wall defining and partially surrounding a combustion chamber;

providing a pre-cast smoke plenum section upon the central body, and comprising transition surfaces for directing smoke to a chimney; and

providing a front portion, comprising pre-cast vermiculite concrete, defining a box aperture opening into the combustion chamber;

locating a facade around the firebox, comprising the step of locating a lightweight frame; and

extending a metal mesh between the lightweight frame and the fire box, and fixedly securing the metal mesh to the lightweight frame and the front portion around the box aperture opening.

17. The method of claim 16 further comprising the step of providing directing air to the combustion chamber with a rectangular flume.