Customizable Patterned Firebacks for Fireplaces

Description

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. App. No. 63/721,798, filed Nov. 18, 2024, the disclosure of which is incorporated herein by reference in its entirety for all purposes.

FIELD

The present disclosure relates generally to fireplaces, and more specifically to fireplaces implementing a fireback.

BACKGROUND

Options for a refractory material as used in the walls of gas (or wood) fireplaces typically include fiber and glass material types that can withstand the heat of the flame within the fireplace. Such material can provide a simple background appearance for the users of the fireplace, such as a design mimicking that of a layered brick or stone wall. They also provide a relatively limited set of options for both material and visual aesthetics as implemented. There is a need to provide users with broader options for customization with respect to the design of the fireplace.

SUMMARY

Fireplaces as disclosed herein, including but not limited to gas fireplace, wood-burning fireplace, and/or simulated-flame or electric fireplace, are provided with one or more options for customizable patterned firebacks that can be installed, removed, and replaced, for example by the user of the fireplace, without requiring complex processes that may potentially damage the fireplace.

The fireback may include one or more patterns that are formed by partially cutting or otherwise separating a portion(s) of a sheet(s) of heat-resistant material (e.g., metal), and the partially cut portions are subsequently moved, rotated, twisted, and/or bent by any suitable angle in a vertical direction, horizontal direction, or angled direction, for example, with respect to the portions that are not cut.

According to an example (“Example 1”), a fireback for a fireplace includes one or more sheets of heat-resistant material including partially cut portions that are bent at an angle in a direction to form one or more patterns on a surface of the one or more sheets of the heat-resistant material.

In another example (“Example 2”) further to Example 1, the direction includes one or more of a vertical direction, a horizontal direction, or an angled direction.

In another example (“Example 3”) further to Example 2, the one or more sheets of the heat-resistant material include uncut portions defining one or more hinges at which the partially cut portions are separately bent.

In another example (“Example 4”) further to Example 1, the heat-resistant material comprises a metal alloy capable of withstanding temperatures of at least approximately 1000 degrees Celsius without experiencing damage or significant deformation.

In another example (“Example 5”) further to Example 1, the one or more patterns include a non-flat pattern comprising first portions forming outward protrusions with respect to a plane defined by the one or more sheets of the heat-resistant material.

In another example (“Example 6”) further to Example 5, the non-flat pattern includes second portions forming inward depressions with respect to the first portions.

In another example (“Example 7”) further to Example 6, the second portions are coplanar with the plane defined by the one or more sheets of the heat-resistant material

In another example (“Example 8”) further to Example 1, the one or more patterns include an alternating pattern comprising first portions of the one or more sheets of the heat-resistant material that protrude in different angles relative to second portions of the one or more sheets of the heat-resistant material adjacent to the first portions in an alternating manner.

In another example (“Example 9”) further to Example 1, the one or more patterns include a three-dimensional visual pattern comprising an arrangement of rhombi to provide an optical illusion of depth.

In another example (“Example 10”), a fireplace includes: a firebox having a refractory wall that defines a semi-enclosed region; and a fireback in the semi-enclosed region proximal to the refractory wall. The fireback includes one or more sheets of heat-resistant material including partially cut portions that are separately bent at an angle in a direction to form one or more patterns on a surface of the one or more sheets of the heat-resistant material.

In another example (“Example 11”) further to Example 10, the fireplace includes one or more lighting components between the fireback and the refractory wall.

In another example (“Example 12”) further to Example 11, the one or more lighting components are configured to illuminate the fireback from various angles to create one or more shadow patterns and highlight three-dimensional aspects of the one or more patterns on the surface of the one or more sheets of the heat-resistant material.

In another example (“Example 13”) further to Example 12, the one or more lighting components are adjustable in one or more of intensity, color, or direction to provide customizable visual effects.

In another example (“Example 14”) further to Example 10, the direction includes one or more of a vertical direction, a horizontal direction, or an angled direction.

In another example (“Example 15”) further to Example 14, the one or more sheets of the heat-resistant material include uncut portions defining one or more hinges at which the partially cut portions are separately bent.

In another example (“Example 16”) further to Example 10, the heat-resistant material of the firebox comprises a metal alloy capable of withstanding temperatures of at least approximately 1000 degrees Celsius without experiencing damage or significant deformation.

In another example (“Example 17”) further to Example 10, the one or more patterns include a non-flat pattern comprising first portions forming outward protrusions with respect to a plane defined by the one or more sheets of the heat-resistant material and second portions forming inward depressions with respect to the first portions. The second portions are in line with the plane defined by the one or more sheets of the heat-resistant material

In another example (“Example 18”) further to Example 10, the one or more patterns include an alternating pattern comprising first portions of the one or more sheets of the heat-resistant material that protrude in different angles relative to second portions of the one or more sheets of the heat-resistant material adjacent to the first portions in an alternating manner.

In another example (“Example 19”) further to Example 10, the one or more patterns include a three-dimensional visual pattern comprising an arrangement of rhombi to provide an optical illusion of depth on a substantially flat surface defined by the one or more sheets of the heat-resistant material.

In another example (“Example 20”) further to Example 10, the fireback comprises a back portion positioned adjacent to a rear wall of the firebox, and one or more side portions positioned adjacent to one or more side walls of the firebox.

While multiple embodiments are disclosed, still other embodiments will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are included to provide a further understanding of the disclosure and are incorporated in and constitute a part of this specification, illustrate embodiments, and together with the description serve to explain the principles of the disclosure.

FIG. 1 is a schematic diagram of a top-down view of a fireplace according to embodiments disclosed herein.

FIG. 2 is an angled view of a fireback standing upright according to embodiments disclosed herein.

FIG. 3 is an angled view of another fireback placed flat on a surface according to embodiments disclosed herein.

FIG. 4 is a front view of another fireback standing upright according to embodiments disclosed herein.

FIG. 5 is a close-up view of another fireback standing upright according to embodiments disclosed herein.

FIG. 6 is a front view of a wood-burning fireplace implementing another fireback according to embodiments disclosed herein.

FIG. 7 is an angled view of a gas fireplace implementing another fireback according to embodiments disclosed herein.

FIG. 8 is a front view of a gas fireplace implementing another fireback according to embodiments disclosed herein.

FIG. 9 is a close-up view of a portion of a sheet of fireback material that is partially cut according to embodiments disclosed herein.

DETAILED DESCRIPTION

The following description sets forth exemplary aspects of the present disclosure. It should be recognized, however, that such description is not intended as a limitation on the scope of the present disclosure. Rather, the description also encompasses combinations and modifications to those exemplary aspects described herein.

The present disclosure relates to customizable patterned firebacks for fireplaces that provide enhanced aesthetic options and light interaction capabilities. The firebacks may be constructed from heat-resistant materials and feature configurable patterns that can be adjusted by users or installers to achieve various visual effects.

Referring to FIG. 1, a fireplace includes a firebox 100 that defines an enclosure for containing flames, or simulated flames, during operation. The firebox 100 may include refractory panels or walls 130 that at least partially surround a semi-enclosed region 140. The semi-enclosed region 140 includes a base 160 on which flames 101 are generated during fireplace operation. In some aspects, the fireplace may include a protective shield 170 positioned at an open portion of the firebox 100 to prevent users from directly accessing the interior region during operation.

The fireplace may be configured as a gas fireplace, wood-burning fireplace, simulated-flame or electric fireplace, or other suitable type of fireplace. In gas fireplace configurations, the base 160 may include gas burner components and decorative media such as artificial logs 600 or crystals 610 as shown in FIGS. 6 and 7. In wood-burning configurations, the base 160 may accommodate actual logs and related combustion materials.

Referring back to FIG. 1, a fireback 110 is positioned within the firebox 100 to provide decorative and/or functional benefits. The fireback 110 may be constructed from one or more sheets 200 of heat-resistant material as shown in FIG. 2. In some aspects, the heat-resistant material comprises metal or metal alloy selected for its ability to withstand elevated temperatures encountered in fireplace operation, such as for example temperatures of at least approximately 1000 degrees Celsius, or temperatures ranging up to approximately 1000 degrees Celsius, or temperatures ranging up to approximately 1300 degrees Celsius, without experiencing damage or significant deformation. Examples of suitable heat-resistant metals include steel such as stainless steel and/or carbon steel, nickel-based alloys, and other high-temperature alloys specifically designed for fireplace and high-heat applications.

As shown in FIG. 1, the fireback 110 may include multiple portions configured to correspond with different areas of the firebox 100. For example, the fireback 110 may include a back portion 110C positioned adjacent to a rear wall of the firebox 100, and one or more side portions 110A and 110B positioned adjacent to one or more side walls of the firebox 100. The number and configuration of fireback portions may be adapted based on factors such as the specific geometry and dimensions of the firebox 100.

The fireback 110 may be positioned proximal to or adjacent to the refractory walls 130 of the firebox 100. In some configurations, the fireback 110 may be spaced apart from the refractory walls 130 to create an air gap that may accommodate additional components or provide thermal insulation benefits.

As shown in FIG. 2, the sheets 200 of heat-resistant material include a plurality of cutout portions 210 formed therein. The cutout portions 210 may be created through various cutting or separating processes, such as laser cutting, water jet cutting, plasma cutting, or other suitable material removal or material separation techniques. The cutout portions 210 are formed via through-cuts that extend completely through the thickness of the sheets 200, creating apertures in the material. In some examples, the apertures may be formed by moving, rotating, twisting, and/or bending partially cut portions of the sheets 200, or the apertures may be formed by removing a portion of the sheets 200 that is cut in a predetermined shape, such as a circle, a polygon, or the like.

The cutout portions 210 may be arranged in one or more patterns 220 across the surface of the sheets 200. The patterns 220 may be predetermined, and may include geometric shapes such as diamonds, squares, rectangles, circles, ovals, or other polygonal configurations. The specific shape, size, and arrangement of cutout portions 210 may be selected to achieve desired aesthetic effects and light interaction characteristics.

In some aspects, the cutout portions 210 are formed as partially cut portions that remain connected to adjacent material of the sheets 200. This configuration allows portions of the sheets 200 to be repositioned without being completely removed or disconnected from the overall structure. The partially cut portions may be moved, rotated, twisted, or bent to various angles (e.g., from 5 to 10 degrees, from 10 to 15 degrees, from 15 to 20 degrees, from 20 to 30 degrees, from 30 to 40 degrees, from 40 to 50 degrees, from 50 to 60 degrees, from 60 to 70 degrees, from 70 to 80 degrees, from 80 to 90 degrees, or any other suitable angle or range therebetween) and orientations (e.g., forward, backward, outward, inward, and/or the like), as shown by the moved portions 230, with respect to the portions that are not cut (uncut portions). In some examples, the portions that are not cut form one or more hinges (e.g., hinges 900 in FIG. 9) where the cut portions may be moved, rotated, twisted, or bent.

As shown in FIG. 3, the fireback 110 may implement various types of three-dimensional patterns 220 to create visual depth and enhanced light interaction. These patterns may include non-flat patterns 220A, alternating patterns 220B, and three-dimensional visual patterns 220C.

In some examples, non-flat patterns 220A may include portions of the sheets 200 that are positioned to protrude from the nominal surface plane. The protrusions formed may be directed in two opposing directions with respect to a plane defined by a surface of the sheet(s) 200. For example, some portions (e.g., first portions) may be bent to create outward (or upward) protrusions with respect to the plane in an inverse-V-shaped mountain configuration 300, while other portions (e.g. second portions) may be bent to create inward (or downward) depressions in a V-shaped valley configuration 310 with respect to the other portions (e.g., first portions). This creates a textured surface with varying depths and angles. In some examples, the first portions are the only protruded portions, and the second portions are in line or are generally co-planar with the plane (e.g., not displaced with respect to the plane).

In some examples, alternating patterns 220B may include portions (e.g., first portions) of the sheets 200 that protrude in different angles or directions relative to adjacent portions (e.g. second portions) of the sheets 200 in an alternating manner. For example, the pattern may include outward protrusions 320 positioned alongside inward protrusions 330, creating a surface with alternating directional elements that interact differently with incident light. In some examples, the portions protrude in different angles relative to the vertical axis of the fireback 110 when the fireback 110 is placed in an upright position in a firebox 100 of a fireplace.

In some examples, three-dimensional visual patterns 220C may be configured to provide optical illusions of depth on substantially flat surfaces, such as the sheets 200. For example, such patterns may create the visual appearance of stacked cubes or other geometric forms viewed from specific angles. These optical effects may be achieved by positioning portions of the sheets 200 at carefully selected angles such that light reflection creates areas of varying brightness and shadow. For example, the three-dimensional visual pattern 220C may include an arrangement of rhombi to provide an optical illusion of depth on a substantially flat surface defined by the one or more sheets 200 of the heat-resistant material (e.g., an optical illusion of having an arrangement of stacked cubes). In some examples, the three-dimensional visual pattern 220C may be achieved by rotating portions of the sheet 200 at different angles such that light reflection from the various surfaces creates areas of varying brightness and darkness, producing the desired visual effect.

As shown in FIG. 4, the fireback 110 may be configured to interact with light from flames 101 and other light sources in various ways. Different portions of the fireback 110 may reflect different amounts of light based on their angular orientation and surface characteristics. For example, an upper reflecting portion 400 of the fireback 110 may reflect less light than a lower reflecting portion 410, creating visual gradients and depth effects. The upper reflecting portion 400 and the lower reflecting portion 410 may be configured different to achieve such effect, such as having different surface layer treatment (e.g., one may be smoother than the other to reflect more light).

As shown for example in FIG. 1, in some aspects, the fireplace may include one or more lighting components 150 positioned proximal to the fireback 110. The lighting components 150 may comprise heat-resistant electric lights or other suitable illumination devices. The lighting components 150 may be positioned between the fireback 110 and the surrounding refractory walls 130 to provide backlighting or accent lighting effects.

The lighting components 150 may be configured to illuminate the fireback 110 from various angles, creating different shadow patterns and highlighting the three-dimensional aspects of the patterns 220. The lighting may be adjustable in intensity, color, or direction to provide customizable visual effects.

As shown in FIG. 5, the fireback 110 may include portions or panels 500 that are visually colored differently to enhance pattern visibility and aesthetic appeal. For example, a first panel 500A may be painted or treated with a different color than an adjacent second panel 500B. This color differentiation may create recognizable patterns such as arrows, geometric shapes, or other decorative motifs. Color variations may be achieved through various methods including painting, powder coating, or other surface treatment processes and/or chemical processes suitable for high-temperature applications that are capable of altering the surface appearance of the metal material.

In some examples, the color variation is caused by portions of the one or more sheets 200 of heat-resistant material being cut to form cut portions and the cut portions are bent outwardly and/or inwardly with respect to the plane defined by the sheets 200. When light passes through the gap (e.g., gap 910 in FIG. 9) between the sheets 200 and the cut portions, the light reflects off of the surface of the cut portions such that the cut portions would appear to have different colors with respect to the remaining portions of the sheets 200.

In some examples, the lighting components 150 may be used in conjunction with colored surfaces to enhance color visibility and create dynamic lighting effects. Even without applied colors, the varying angles of bent portions may create apparent color differences due to different amounts of light reflection from surfaces oriented at different angles.

The fireback 110 may be designed for installation, removal, and replacement by users without requiring complex procedures that might damage the existing fireplace structure. The fireback 110 may be configured as a separate component from the firebox 100, allowing for easy customization and maintenance.

In some aspects, the fireback 110 may be provided in flat-packed configurations for efficient shipping and storage. The patterns 220 may be pre-cut during manufacturing, with final forming and positioning of cut portions performed during installation or by end users according to their preferences.

The adjustable nature of the partially cut portions allows users to modify the appearance of the fireback 110 over time, providing ongoing customization options. Different angular configurations may create different shadowing and reflection properties, allowing users to adapt the visual characteristics to match changing preferences or seasonal decorating themes.

In some embodiments, the fireback 110 may be implemented as a metal-overlay system that enhances existing refractory panels. In such configurations, cut components 210 may be formed as separate elements that are attached to or positioned on the surface of existing refractory panels or walls 130.

As shown in FIG. 8, the metal-overlay approach may create visual patterns where darker portions correspond to the cut components 210 and lighter portions correspond to exposed areas of the underlying refractory material, such as the refractory panels or walls 130. This configuration may provide three-dimensional visual effects, such as the appearance of a grid pattern with optical depth illusions, while utilizing existing fireplace infrastructure.

The fireback 110 may be adapted for use in various fireplace configurations. As shown in FIG. 6, for example, in traditional wood-burning fireplaces, the fireback 110 may be positioned to surround logs 600 and other combustion materials, providing an enhanced backdrop for the fire display.

As shown in FIGS. 7 and 8, in linear fireplace configurations, the fireback 110 may be configured with patterns 220 that complement the elongated geometry of such fireplaces. The linear arrangement may emphasize certain pattern characteristics and create unique light interaction effects suited to the specific fireplace design.

FIG. 9 shows a sheet 200 of the fireback material that is partially cut out and disposed to form one or more differently lit portions according to embodiments disclosed herein. For example, the sheet 200 includes two different cutout portions: a first cutout portion 210A and a second cutout portion 210B. The cutout portion 210 is formed by partially cutting the sheet 200 while leaving a portion intact. The intact portion may form a hinge 900 allowing the other partially cut portion of the sheet 200 to be displaced (e.g., moved, rotated, twisted, and/or bent) by any suitable angle with respect to the plane defined by the sheet 200. For example, the first cutout portion 210A has an outward protrusion 320 formed by displacing the partially cut portion of the sheet 200 outwardly with respect to the plane such that a gap 910 is formed between the edge of the partially cut portion and the sheet 200. The second cutout portion 210B has an inward protrusion 330 formed by displacing the partially cut portion of the sheet 200 inwardly with respect to the plane, forming the gap 910.

The cutout portions 910 react differently to the incident light provided by the lighting component 150. For simplicity, the lighting component 150 is shown to be located on the front side of the sheet 200 underneath the cutout portions 210. In this position, the lighting component 150 causes the color of a front-facing surface of the outward protrusion 320 in the cutout portion 210A to be darker (as shown by the shading) because it is in the shadows, whereas the color of a front-facing surface of the inward protrusion 330 in the cutout portion 210B may be lighter because it reflects the incident light. Different degrees of protrusion with respect to the sheet 200 may also cause different colors to be shown on the surface of the sheet 200. The positions of the darker portion and the lighter portion of the cutout portions 210 would also change when the location of the lighting component 150 is changed (e.g., moved to above the cutout portions 210 instead of underneath as shown in the figure).

Gas fireplaces may incorporate the fireback 110 in conjunction with decorative media such as crystals 610 or artificial logs 600. The combination of the patterned fireback 110 with reflective media may create enhanced light dispersion and visual effects.

The customizable fireback 110 provides several advantages over traditional refractory materials. The metal or other material construction may utilize sustainable resources and can be manufactured and shipped in efficient flat-pack configurations. The through-cut design enables enhanced or more flexible light interaction capabilities that conventional refractory panels cannot provide.

The adjustable configuration options allow fireplaces to exhibit different shadowing and reflection properties based on user preferences and setup configurations. This flexibility enables users to match interior design themes and coordinate the fireplace appearance with other decorative elements in the surrounding space.

The variety of available patterns 220 and the ability to modify these patterns over time provides users with extensive customization options to enhance their fire experience. The aesthetic flexibility allows the interior appearance of the firebox to be coordinated with exterior wall art and other design elements for improved overall visual integration.

Numerous characteristics and advantages have been set forth in the preceding description, including various alternatives together with details of the structure and function of the devices and/or methods. Moreover, the scope of the various concepts addressed in this disclosure has been described both generically and with regard to specific examples. The disclosure is intended as illustrative only and as such is not intended to be exhaustive. It will be evident to those skilled in the art that various modifications may be made, especially in matters of structure, materials, elements, components, shape, size, and arrangement of parts including combinations within the principles of the disclosure, to the full extent indicated by the broad, general meaning of the terms in which the appended claims are expressed. To the extent that these various modifications do not depart from the spirit and scope of the appended claims, they are intended to be encompassed therein.