Modular Assembly for Electric Fireplace

This patent application is a continuation patent application that claims the benefit under 35 U.S.C. 120 on co-pending U.S. patent application Ser. No. 17/824,468, filed on May 25, 2022, and entitled MODULAR ASSEMBLY FOR ELECTRIC FIREPLACE”. U.S. application Ser. No. 17/824,468 further claims the benefit under 35 U.S.C. 120 on U.S. patent application Ser. No. 17/474,852, filed on Sep. 14, 2021, and entitled “MODULAR ASSEMBLY FOR ELECTRIC FIREPLACE”, and issued on Jan. 9, 2024, as U.S. Pat. No. 11,867,409. U.S. patent application Ser. No. 17/474,852 further claims priority on U.S. Provisional Patent Application Ser. No. 63/192,784, entitled “MODULAR ASSEMBLY FOR ELECTRIC FIREPLACE, filed on May 25, 2021. U.S. patent application Ser. No. 17/474,852 further claims the benefit under 35 U.S.C. 120 on U.S. patent application Ser. No. 16/714,310, filed on Dec. 13, 2019, and entitled “MODULAR ASSEMBLY FOR ELECTRIC FIREPLACE”, and issued on Apr. 4, 2023, as U.S. Pat. No. 11,619,390. Further, U.S. patent application Ser. No. 16/714,310 claims priority on U.S. Provisional Patent Application Ser. No. 62/905,077, entitled “MODULAR ASSEMBLY FOR ELECTRIC FIREPLACE”, filed on Sep. 24, 2019. As far as permitted, the contents of U.S. patent application Ser. Nos. 17/824,468, 17/474,852, 63/192,784, 16/714,310, and 62/905,077 are incorporated in their entirety herein by reference.

Fireplaces of various types can be installed in homes and commercial establishments as a means to provide a source of heat and for aesthetic reasons. Although traditionally such fireplaces have most often taken the form of wood-burning fireplaces and gas-burning fireplaces, electric fireplaces have become increasingly popular in recent years. An electric fireplace is typically designed to look like a traditional wood-burning fireplace, but does not actually burn wood. As such, there is a continuing desire to make electric fireplaces look more realistic, i.e. to make electric fireplaces look more like a traditional wood-burning fireplace.

Unfortunately, in currently available electric fireplaces, mantel and/or insert portions, which commonly contain a fireplace housing, a grate, simulated logs, a heater, a flame generator and a glass frame, typically comes completely assembled and wired, and thus takes up a lot of space for packaging, shipping and storing. Additionally, since such inserts typically come already assembled, such currently available electric fireplaces also do not generally allow for substantial variability for the consumer in terms of the overall size, shape, design and aesthetic appearance of the electric fireplace.

is a simplified side view illustration of a prior art embodiment of an electric fireplaceP and a cabinet assemblyB, and a package assemblyP that can be utilized to contain the electric fireplaceP and the cabinet assemblyP. The package assemblyP is illustrated as being substantially transparent inso that the electric fireplaceP and the cabinet assemblyB can be seen as packaged within the package assemblyP. As shown in this prior art embodiment, the electric fireplaceP is fully assembled within the package assemblyP, which is how prior art electric fireplaces are packaged, shipped and stored, and arrive to the consumer.

As shown in, with a standard-sized cabinet assemblyB, which can be packaged in an unassembled configuration, and the fully assembled electric fireplaceP, in certain embodiments, the package assemblyP can have an assembly lengthL of between approximately 1065 millimeters (approximately 42 inches) and 1525 millimeters (approximately 60 inches). In one embodiment, the package assemblyP can have an assembly lengthL of approximately 1310 millimeters (approximately 51.5 inches).

is a simplified end view illustration of the prior art electric fireplaceP, cabinet assemblyB and package assemblyP illustrated in. The package assemblyP is again illustrated as being substantially transparent inso that the electric fireplaceP and the cabinet assemblyB can be seen as packaged within the package assemblyP. As shown in, in some embodiments, the package assemblyP can have an assembly widthW of between approximately 380 millimeters (approximately 15 inches) and 560 millimeters (approximately 22 inches). In one embodiment, the package assemblyP can have an assembly widthW of approximately 470 millimeters (approximately 18.5 inches).

Additionally,further illustrates that in certain embodiments, the package assemblyP can have an assembly heightH of between approximately 460 millimeters (approximately 18 inches) and 610 millimeters (approximately 24 inches). In one embodiment, the package assemblyP can have an assembly heightH of approximately 525 millimeters (approximately 20.75 inches). As shown, the assembly heightH of the package assemblyP must be sufficiently large to effectively contain the electric fireplacewhich is packaged and comes to the consumer fully assembled.

Thus, there is a desire to allow greater variety in the size, shape, design and aesthetic appearance of the electric fireplace for the consumer, while still enabling various product development, packaging, shipping, storing and overall cost efficiencies. Additionally, there is also a desire to enable the consumer to easily and safely connect all electrical components within the electric fireplace.

The present invention is directed toward an electric fireplace including a fireplace housing and a heater assembly that is configured to generate heated air. The heater assembly is configured to be installed substantially within the fireplace housing. In various embodiments, the heater assembly includes a heater body, and a grill cover that is couplable to the heater body. In various embodiments, the grill cover includes a cover body that is couplable to the heater body, and at least one extender that is configured to be positioned substantially adjacent to the cover body. The cover body has a first cover length. The cover body and the at least one extender cooperate to have a second cover length that is greater than the first cover length. The second cover length is substantially equal to a dimension of the fireplace housing.

In some embodiments, the heater body has a body length; and the first cover length is substantially equal to the body length.

In certain embodiments, the at least one extender is configured to be positioned substantially adjacent to an outer lateral edge of the cover body.

In some embodiments, the grill cover includes two extenders, with one extender positioned substantially adjacent to each of the outer lateral edges of the cover body.

In certain embodiments, the second cover length is at least approximately 100 millimeters greater than the first cover length.

In various embodiments, the electric fireplace further includes a controller including a processor that is coupled to the heater assembly, the controller being configured to control operation of the heater assembly.

In certain embodiments, the electric fireplace also includes one or more simulated logs and a grate that is configured to support the one or more simulated logs. The one or more simulated logs and the grate are configured to be positioned substantially within the fireplace housing.

In some embodiments, the electric fireplace further includes a flame generator that is configured to generate a simulated flame, the heater assembly and the flame generator being installed independently of one another within the fireplace housing.

In various embodiments, the electric fireplace further includes an electrical connection assembly for electrically connecting the heater assembly and the flame generator to a power source, the electrical connection assembly including (i) a first electrical cable assembly that is configured to be electrically coupled at one end to the heater assembly, and electrically coupled at the other end to the power source; and (ii) a second electrical cable assembly that is configured to be electrically coupled at one end to the heater assembly, and electrically coupled at the other end to the flame generator.

In certain embodiments, the first electrical cable assembly includes an AC power cord; and the second electrical cable assembly includes a low voltage cable such as a USB cable or other suitable cable.

In some embodiments, the electric fireplace further includes a downlight light source that is configured to direct light in a downward direction within the fireplace housing to provide a glowing effect for the fireplace housing.

In various embodiments, the electric fireplace further includes a cabinet that defines a structural opening. The fireplace housing and the heater assembly are configured to be independently installed within the structural opening of the cabinet. Additionally, the second cover length is substantially equal to a dimension of the structural opening.

The present invention is further directed toward an electric fireplace including a cabinet that defines a structural opening; and a heater assembly that is configured to generate heated air, the heater assembly being configured to be installed substantially within the structural opening. The heater assembly includes a heater body, and a grill cover that is couplable to the heater body. The grill cover includes a cover body that is couplable to the heater body, and at least one extender that is configured to be positioned substantially adjacent to the cover body. The cover body has a first cover length, and the cover body and the at least one extender cooperate to have a second cover length that is greater than the first cover length. The second cover length is substantially equal to a dimension of the structural opening.

Embodiments of the present invention are described herein in the context of a modular assembly for an electric fireplace. More particularly, the modular assembly and design for the electric fireplace enables greater flexibility to the consumer for the overall design of the electric fireplace, as well as offering various cost and product development efficiencies. For example, numerous options for different components of the electric fireplace can be incorporated together in any desired manner to provide various alternatives for the consumer in terms of the overall size, shape, design and aesthetic appearance of the electric fireplace. Additionally, in certain embodiments, some of the components of the electric fireplace can be positioned in different locations within the electric fireplace depending on the preferences of the consumer and/or the design of the cabinet in which the electric fireplace is installed. Further, in various embodiments, certain components of the electric fireplace can be interchangeable with other similar, alternative components in order to provide a different overall aesthetic appearance and/or to fit within alternative cabinet assemblies with different sized and/or shaped structural openings. Additionally, in certain embodiments, the components of the electric fireplace can be configured relative to one another so that they can be packaged together much more compactly, which can provide even further cost efficiencies. Still further, in some embodiments, electrical connections for certain components of the electric fireplace can be configured to enable the consumer to easily and safely establish such electrical connections so that power is provided to all such electrical components of the electric fireplace. Yet further, in certain embodiments, the cabinet can also be provided to the consumer in the form of a modular cabinet assembly that is configured to be assembled, along with the electric fireplace, by the consumer.

Those of ordinary skill in the art will realize that the following detailed description of the present invention is illustrative only and is not intended to be in any way limiting. Other embodiments of the present invention will readily suggest themselves to such skilled persons having the benefit of this disclosure. Reference will now be made in detail to implementations of the present invention as illustrated in the accompanying drawings.

In the interest of clarity, not all of the routine features of the implementations described herein are shown and described. It will, of course, be appreciated that in the development of any such actual implementation, numerous implementation-specific decisions must be made in order to achieve the developer's specific goals, such as compliance with application-related and business-related constraints, and that these specific goals will vary from one implementation to another and from one developer to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking of engineering for those of ordinary skill in the art having the benefit of this disclosure.

is a front perspective view illustration of an embodiment of an electric fireplacehaving features of the present invention. Additionally, as shown, the electric fireplaceis positioned and/or integrated into a cabinethaving a structural openingA (illustrated more clearly in) that is configured to receive the electric fireplace. It is appreciated that the cabinetand/or the structural openingA can be of any suitable size, shape and design, which can be different than what is specifically shown in. Thus, the specific size, shape and design of the cabinetand/or the structural openingA illustrated in the Figures is not intended to be limiting in any manner. Additionally, it is further appreciated that in some alternative embodiments, the cabinetcan also be provided in the form of a modular cabinet assemblyB (illustrated, for example, in) that is configured to be assembled by the consumer, prior to and/or in conjunction with the assembly and installation of the electric fireplacewithin the structural openingA of the cabinet.

As illustrated herein, the electric fireplacecan be used to provide heat and to simulate a wood burning fire, e.g., in a room of a home or other type of building. More particularly, in certain embodiments, the electric fireplacecan be configured to look like a traditional wood-burning fireplace, although the electric fireplacedoes not actually burn wood.

The design of the electric fireplacecan be varied. In certain embodiments, as illustrated in, the electric fireplacecan include (i) a fireplace housing; (ii) a viewing areathat is defined within the fireplace housing; (iii) a grate; (iv) a simulated flame(i.e. which is visible when the electric fireplaceis in use); (v) one or more simulated logs; (vi) a light source(illustrated as a box in phantom) and/or a simulated flame generator(also sometimes referred to herein simply as a “flame generator”) that can be used to selectively generate the simulated flameand/or to create a glowing effect for the simulated logs; (vii) a heater assembly; and (viii) a controller. Additionally, although not specifically shown in, the electric fireplacecan further include an electrical connection assembly(illustrated, for example, in) including greatly simplified electrical connections that enable power to be provided to various electrical components of the electric fireplace. Alternatively, the electric fireplacecan include more components or fewer components than those specifically illustrated in. For example, in one non-exclusive alternative embodiment, the electric fireplacecan further include a simulated emberbed. Still alternatively, the various components of the electric fireplacecan be positioned in a different manner than that shown in.

As utilized herein, the fireplace housingis also sometimes referred to generally as a “mantel”, and the additional components of the electric fireplacethat are selectively positioned within the fireplace housing, e.g., during use and/or packaging of the electric fireplace, are also sometimes referred to generally as an “insert”.

As an overview, in certain embodiments, the electric fireplaceis uniquely formed with a modular design such that various components are manufactured and installed independently of one another. Stated in another manner, the electric fireplacecan be constructed via a knock/down (“K/D”) method, and one or more of the components can be K/D components that can be individually installed by the user or consumer. Moreover, certain components of the electric fireplacecan be positioned in different locations within the structural openingA of the cabinetto suit the particular desires of the consumer. With such design, the electric fireplacecan be constructed by the consumer, i.e. at the consumer level, from the component parts, and need not be constructed at the manufacturer/factory level as is done with typical electric fireplaces. Additionally, with such design, the electric fireplaceand the components thereof can be configured to have any suitable size, shape, design and aesthetic appearance depending on the preferences of the consumer. For example, as described herein, the fireplace housingcan be formed from multiple individual components (e.g., a base panel, a back panel, side panelsand a front frame(illustrated more clearly in)) of varying designs, sizes and shapes, which can be configured together to fit within structural openings of different sizes and shapes. Additionally, the design of each of the components of the electric fireplacecan be mixed and matched as desired. Thus, with the modular design described herein, the consumer is provided with a larger variety of options for the overall design (e.g., size, shape and aesthetic appearance) of the electric fireplace, thus enhancing consumer control and happiness, while still enabling various cost and product development efficiencies. Moreover, in some embodiments, the cabinetcan also be constructed via a knock/down (“K/D”) method, with various components of the cabinetbeing assembled by the consumer

Further, in certain embodiments, some components of the electric fireplace, e.g., individual components of the fireplace housingsuch as the back paneland/or the side panels, may be configured to be flexible and/or foldable so as to take up less space when not in use, e.g., during packaging, shipping and/or storage. For example, in such embodiments, the back paneland/or the side panelscan be moved between an unfolded configuration, where such components can be substantially planar in their entirety and are ready for installation (or are actually installed in the electric fireplace), and a folded configuration, where separate segments of such components can be substantially directly adjacent to one another so that the overall components are substantially flat and with a smaller footprint than such components when in the unfolded configuration. Such a segmented back panelis illustrated and described in relation to.

Still further, as provided herein, various components can be configured to fit together compactly when installed and in use, and/or during packaging, shipping and/or storing of the electric fireplace. For example, in some embodiments, as described in greater detail herein below, the heater assemblyand the controllercan be packaged together into an integrated electrical insert, which can be sized and shaped to fit and/or be embedded within a base openingA (illustrated in, and also sometimes referred to as a “base aperture)) that is formed into the base panelso that the size of the combined base paneland electrical insertis not much larger than the size of the base panelby itself. In such embodiments, the combined base paneland electrical insertare also sometimes referred to as a “base module”. Alternatively, the electrical insert, the heater assemblyand/or the controllercan be positioned in another suitable manner within the cabinet.

Thus, with such design, all of the components of the electric fireplacecan be provided in a much smaller overall package, e.g., similar to the size of just the fireplace housing, which can provide various cost efficiencies for shipping, storing, etc. Stated in another manner, the packaging size of the full electric fireplace, i.e. the mantel plus the insert, is roughly the same size as the packaging size for only a typical mantel. It is further appreciated that in embodiments where the cabinet is also assembled via the K/D method, the combined packaging of the cabinetand the electric fireplacecan provide even additional cost efficiencies for packaging, shipping, storing, etc. based on the smaller overall packaging that would be required to contain all components of the cabinetand the electric fireplace.

Moreover, with the product design as described in detail herein, the various components of the fireplace housing, and the electric fireplacein general, can be manufactured independently of one another, and then such components, e.g., the base panel, the back panel, the side panels, the electrical insert, the grate, the simulated logs, etc., can be installed independently of one another at the consumer level.

Yet further, due to the inclusion of the easy-to-use electrical connection assembly, the consumer is able to easily and safely establish all necessary electrical connections, e.g., between the electrical insert(the heater assemblyand/or the controller) and the grate(the light sourceand/or the flame generator), and between the electric insert(the heater assemblyand/or the controller) and/or the grateand an external power source(illustrated as a box) such as an electrical outlet.

Upon installation of the electric fireplace, the fireplace housingcan be sized and shaped to retain most, if not all, of the remaining components of the electric fireplace. In particular, in many embodiments, the grate, the simulated flame(i.e. when the electric fireplaceis in use), the one or more simulated logs, the light source, the flame generator, the heater assemblyand the controllercan be positioned substantially within the fireplace housingonce the electric fireplacehas been installed and prepared for use. In some embodiments, as shown in, the fireplace housingcan be installed and configured to have a substantially rectangular shape. Alternatively, the fireplace housingcan be installed and configured to have a different shape depending on the preferences of the consumer and the limitations of the structural openingA within which the electric fireplaceis being installed.

Further, the fireplace housing, and the various individual components thereof, can be formed from any suitable materials. For example, in some embodiments, the fireplace housing, and the various individual components thereof, can be formed from any of a number of suitable metallic materials. Alternatively, the fireplace housing, and the various individual components thereof, can be formed from any other suitable materials.

The viewing areais the area within the fireplace housingin which the grate, the simulated flame, the simulated logs, and the simulated emberbed (when included) are displayed and can be seen by the user.

As illustrated, the grate, i.e. an actual or simulated grate, is configured to support the simulated logsabove the base panelof the fireplace housing. Additionally, in this embodiment, the gratecan be positioned substantially directly above the base module, i.e. the base paneland/or the electrical insert.

Further, the gratecan also be formed from any suitable materials. For example, in certain non-exclusive alternative embodiments, the gratecan be formed from metallic materials such as a welded steel or aluminum material. Alternatively, the gratecan be formed from plastic, resin, and/or another suitable material.

As shown in, in various embodiments, the simulated flameis displayed within the viewing areaof the electric fireplace. The simulated flameis configured to give the electric fireplacea more realistic appearance, i.e. to make the electric fireplacelook more like a traditional wood-burning fireplace. The simulated flamecan be formed from any suitable method. For example, in various embodiments, the electric fireplacecan utilize the light sourceto illuminate a reflective medium (not shown), e.g., a suitable metal material, to generate the simulated flame, i.e. a flickering flame image. Alternatively, the simulated flamecan be generated through specific use of the flame generatorthat is specifically configured to generate the simulated flame. Still alternatively, the simulated flamecan be generated in another suitable manner.

As noted above, upon installation, the simulated (or artificial) logscan be retained within the fireplace housingand thus positioned within the viewing area. Additionally, in certain embodiments, the simulated logscan utilize the light source, the flame generatorand/or a separate light source to create a glowing effect for the simulated logs. Thus, the combination of the simulated logsand the simulated flamecan use the light source, the flame generatorand/or a separate light source to create the appearance of burning logs, thereby closely simulating the flames of a wood-burning fireplace. As illustrated, the simulated logscan further be placed on top of the grate. Alternatively, in one embodiment, the simulated logscan be integrally formed with the grate.

Additionally, the simulated logscan be formed from any suitable materials. For example, in certain non-exclusive alternative embodiments, the simulated logscan be hollow molded logs that are formed from a molded resin material. Alternatively, the simulated logscan be formed from another suitable material.

In some embodiments, when included as part of the electric fireplace, the simulated emberbed can be positioned adjacent to the base panelof the fireplace housingand substantially directly below the grate. Additionally, the simulated emberbed can also utilize the light source, the flame generatorand/or a separate light source to create a glowing effect for the simulated emberbed. It is appreciated that the glowing effect for the simulated emberbed can further enhance the overall look of the electric fireplaceto be more like that of a traditional wood-burning fireplace.

Further, the simulated emberbed can be formed from any suitable materials. For example, in certain non-exclusive alternative embodiments, the simulated emberbed can be formed from a molded resin material. Alternatively, the simulated emberbed can be formed from another suitable material.

As noted above, the light sourcecan be configured to assist in the generation of the simulated flame, as well as helping to create the glowing effect for the simulated logsand/or the simulated emberbed. Stated in another manner, the light sourcecan be utilized, i.e. selectively activated, for purposes of generating the simulated flame, creating a glowing effect for the simulated logs, and/or creating a glowing effect for the simulated emberbed.

The light sourcecan have any suitable design. For example, in one non-exclusive alternative embodiment, the light sourcecan include a flat, PCB board upon which is mounted an LED panel having one or more LED light bulbs. It is appreciated that the use of LED light bulbs makes it generally unnecessary to access the light sourceas the LED light bulbs have a very long, life span and do not need to be regularly replaced. Alternatively, the light sourcecan have another suitable design, e.g., can include other types of light bulbs or another type of light source. Additionally, the light sourcecan be positioned in any suitable manner for purposes of more effectively generating the simulated flame, creating a glowing effect for the simulated logs, and/or creating a glowing effect for the simulated emberbed, as desired.

In some embodiments, the light sourcecan be incorporated and/or formed into the structure of the grate. Thus, with the light sourceincorporated into the grate, additional size and space efficiencies can be achieved. Additionally, with such design, electrical connection to the light sourcecan be provided via the grate, e.g., via electrical connection ports coupled to the light sourcevia the grateand electrical connectors that can be coupled into the electrical connection ports. Alternatively, the light sourcecan be provided independently of the grate.

Similarly, as noted above, the flame generatorcan also or alternatively be configured to assist in the generation of the simulated flame, as well as helping to create the glowing effect for the simulated logsand/or the simulated emberbed. Stated in another manner, the flame generatorcan be utilized, i.e. selectively activated, in conjunction with the light sourceor in lieu of the light source, for purposes of generating the simulated flame, creating a glowing effect for the simulated logs, and/or creating a glowing effect for the simulated emberbed.

In some embodiments, the flame generatorcan be incorporated and/or formed into the structure of the grate. Thus, with the flame generatorincorporated into the grate, additional size and space efficiencies can be achieved. Additionally, with such design, electrical connection to the flame generatorcan be provided via the grate, e.g., via electrical connection ports coupled to the flame generatorvia the grateand electrical connectors that can be coupled into the electrical connection ports. Alternatively, the flame generatorcan be provided independently of the grate.

Further, in certain embodiments, the grateand the light sourceand/or the flame generator, as well as the simulated logs, can be independent components that can be installed within the structural openingA by the user. Still further, in some embodiments, the gratewith the light sourceand/or the flame generator, as well as the simulated logs, can be provided together and can be positioned on top of the base module, i.e. the base paneland/or the electrical insert, during packaging and/or during use of the electric fireplace.