Flame simulating assembly

• US 8,361,367 B2
• Filed: 11/29/2011
• Issued: 01/29/2013
• Est. Priority Date: 11/17/2004
• Status: Active Grant

• Current Assignee: Glen Dimplex Americas, Ltd. (Glen Dimplex Plc)
• Original Assignee: Dimplex North America Ltd. (Glen Dimplex Plc)
• Inventors: Hess, Kristoffer, Champ, Martyn, Jach, Michael, Stinson, Kelly
• Primary Examiner(s): THEISEN, MARY LYNN F
• Application Number:
  US13/306,480
• Publication Number:
  US 20120070583A1
• Time in Patent Office: 427 Days
• Field of Search: None
• US Class Current: 264/225
• CPC Class Codes: B05D 5/00 Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
• CPC Class Codes: F24B 1/1808 Simulated fireplaces
• CPC Class Codes: F24C 7/004 simulating flames
• CPC Class Codes: G09F 19/12 using special optical effects

Abstract

A method of forming a simulated combustible fuel element for simulating a semi-burned combustible fuel element, including, first, covering a surface of the semi-burned combustible fuel element with a material selected to produce a resiliently flexible mold, and second, after the selected material has set, removing the semi-burned combustible fuel element from the mold. Next, a predetermined amount of liquefied body material is introduced into the mold, and a body is produced resembling the semi-burned combustible fuel element with one or more cavities therein and an exterior surface simulating the surface of the semi-burned combustible fuel element, the body including one or more light passages. After the body material is cured, the mold is removed from the body.

Claims

1. A method of forming a simulated combustible fuel element for simulating a semi-burned combustible fuel element, the method comprising the steps of:

(a) covering a surface of the semi-burned combustible fuel element with a material selected to produce a resiliently flexible mold;

(b) after the selected material has set, removing the semi-burned combustible fuel element from the mold;

(c) introducing a predetermined amount of a liquefied body material into the mold;

(d) rotating the mold to produce a body comprising said body material and resembling the semi-burned combustible fuel element, the predetermined amount being sufficient to provide the body with at least one cavity therein and an exterior surface simulating the surface of the semi-burned combustible fuel element;

(e) curing the body to solidify said body material;

(f) removing the mold from the body;

(g) positioning at least one light source at least partially in said at least one cavity; and

(h) coating at least a portion of the exterior surface in accordance with a predetermined exterior surface pattern to provide;

at least one light-transmitting part positioned in a path of light from said at least one light source, said at least one light-transmitting part being colored to resemble glowing embers of the combustible fuel upon transmission therethrough of light from said at least one light source; and

at least one substantially opaque exterior part for substantially preventing transmission of light from said at least one light source therethrough colored to resemble a non-ember part of the combustible fuel.

2. A method according to claim 1 additionally comprising, after step (f), the step of forming an access hole in the body in communication with said at least one cavity, to permit said at least one light source to be at least partially inserted in said at least one cavity through the access hole.

3. A method according to claim 2 additionally comprising, after said at least one light source is at least partially positioned in said at least one cavity, the step of inserting plug material into the access hole to substantially block the access hole.

4. A method according to claim 1 in which the material of step (a) is silicone rubber.

5. A method of forming a simulated combustible fuel element for simulating a semi-burned combustible fuel element, the method comprising the steps of:

(a) covering a surface of the semi-burned combustible fuel element with a material selected to produce a resiliently flexible mold;

(b) after the selected material has set, removing the semi-burned combustible fuel element from the mold;

(c) introducing a predetermined amount of a liquefied body material into the mold;

(d) rotating the mold to produce a body comprising said body material and resembling the semi-burned combustible fuel element, the predetermined amount being sufficient to provide the body with at least one cavity therein and an exterior surface simulating the surface of the semi-burned combustible fuel element, the body additionally comprising at least one aperture extending between the exterior surface and said at least one cavity;

(e) curing the body to solidify said body material;

(f) removing the mold from the body;

(g) positioning at least one light source in said at least one cavity in relation to said at least one aperture to permit light from said at least one light source to be transmitted through the aperture, to resemble glowing embers of the combustible fuel.

6. A method according to claim 5 in which at least a portion of the exterior surface of the body is coated in accordance with a predetermined exterior surface pattern such that the exterior surface resembles the surface of the semi-burned combustible fuel element.

7. A method according to claim 5 additionally comprising, after step (f), the step of forming an access hole in the body in communication with said at least one cavity, to permit said at least one light source to be at least partially inserted in said at least one cavity through the access hole.

8. A method according to claim 7 additionally comprising, after said at least one light source is at least partially positioned in said at least one cavity, the step of inserting plug material in the access hole to substantially block the access hole.

9. A method according to claim 5 in which the material of step (a) is silicone rubber.

10. A method of forming a simulated combustible fuel element for simulating a semi-burned combustible fuel element, the method comprising the steps of:

(a) covering a surface of the semi-burned combustible fuel element with a material selected to produce a resiliently flexible mold;

(b) after the selected material has set, removing the semi-burned combustible fuel element from the mold;

(c) introducing a predetermined amount of a liquefied body material into the mold;

(d) rotating the mold to produce a body comprising said body material and resembling the semi-burned combustible fuel element, the predetermined amount being sufficient to provide the body with at least one cavity therein and an exterior surface simulating the surface of the semi-burned combustible fuel element, the body comprising at least one light passage;

(e) curing the body to solidify said body material;

(f) removing the mold from the body; and

(g) positioning at least one light source at least partially in said at least one cavity such that said at least one light passage is located in a path of light from said at least one light source, said at least one light passage resembling glowing embers of the combustible fuel upon transmission therethrough of light from said at least one light source.

11. A method according to claim 10 in which said at least one light passage comprises at least one light-transmitting part.

12. A method according to claim 10 in which said at least one light passage comprises at least one aperture extending between the exterior surface and said at least one cavity.