Gas burner

Abstract

A gas burner is provided that simulates wood burning fire and the glowing amber effect of real wood or coal burning. The burner comprises a burner pan which is covered by a refractory material. Burner ports are formed through the refractory material.

1 . A burner comprising: 
 a pan comprising a base surrounded by walls;    a screen surface mounted within the pan and spaced apart from the base;    a ceramic board over the screen, the board having a first surface opposite a second surface and peripheral edges there between, wherein the second surface faces the screen;    a metal strip adjacent each edge; and    a metallic foil sheet wrapped around the second surface and edges exposing the first surface of the ceramic board, wherein the foil extends between the screen and the ceramic board and wherein the metal strips are coupled to the walls forming a closed burner.    
     
     
         2 . A burner as recited in  claim 1  of the burner further comprising a plurality of openings formed through the foil and board defining gas outlet ports.  
     
     
         3 . A burner as recited in  claim 1  wherein a portion of the ceramic board is convex in cross-section.  
     
     
         4 . A burner as recited in  claim 1  wherein the metallic strips are made from a weldable metallic material, wherein the walls are made from a weldable metallic material, and wherein the walls are welded to the strips and whereby the foil between the strips and walls flows during welding and mixes with the strips and walls.  
     
     
         5 . A burner as recited in  claim 1  wherein the foil is attached to the board using an adhesive.  
     
     
         6 . A burner as recited in  claim 1  wherein the metallic foil is made from aluminum.  
     
     
         7 . A burner as recited in  claim 1  wherein the foil is glued to the walls.  
     
     
         8 . A burner as recited in  claim 1  further comprising a plurality of fasteners fastening the board to the screen surface.  
     
     
         9 . A burner as recited in  claim 1  wherein the first surface of the ceramic board comprises carvings.  
     
     
         10 . A burner as recited in  claim 1  wherein the board comprises a density, wherein the density of the board varies through the thickness of the board.  
     
     
         11 . A burner as recited in  claim 10  wherein the density of the board proximate the first surface is less than the density of the board proximate the second surface.  
     
     
         12 . A burner comprising: 
 a pan comprising a base surrounded by walls;    a screen surface mounted within the pan and spaced apart from the base;    a ceramic board over the screen, the board having a first surface opposite a second surface and peripheral edges there between, wherein the second surface faces the screen;    a metal sheet wrapped around the second surface and edges exposing the first surface of the ceramic board, wherein the metal sheet extends between the screen and the ceramic board and wherein the metal sheet is attached to the walls forming a closed burner.    
     
     
         13 . A burner as recited in  claim 12  wherein the metal sheet is welded to the walls.  
     
     
         14 . A burner as recited in  claim 12  wherein the sheet is attached to the walls using an adhesive.  
     
     
         15 . A burner as recited in  claim 12  the burner further comprising a plurality of openings formed through the metal sheet and board defining gas outlet ports.  
     
     
         16 . A burner as recited in  claim 12  wherein the first surface of the ceramic board is carved.  
     
     
         17 . A burner as recited in  claim 12  further comprising a plurality of fasteners fastening the board to the screen surface.  
     
     
         18 . A burner comprising: 
 a pan having a plurality of walls;    a ceramic board having a first surface opposite a second surface and a thickness there through;    a plurality of ports formed through the thickness; and    a slot formed on the first surface, wherein the pan walls are fitted within the slot.    
     
     
         19 . A burner as recited in  claim 18  wherein the walls are in the slots with a ceramic fiber adhesive.  
     
     
         20 . A burner comprising: 
 a pan having a plurality of walls;    a ceramic board having a first surface opposite a second surface and a thickness there through, the ceramic board being mounted over the pan;    a plurality of ports formed through the thickness; and    a plurality of legs extending from the first surface and adjacent to the walls.    
     
     
         21 . A burner as recited in  claim 20  wherein the plurality of legs are bonded to the walls.  
     
     
         22 . A burner as recited in  claim 20  wherein one of said plurality of legs intersects another of said plurality of legs.  
     
     
         23 . A burner as recited in  claim 20  wherein the number of legs is equal to the number of pan walls and wherein each leg is adjacent to one of said pan walls.  
     
     
         24 . A burner as recited in  claim 20  further comprising a plurality of second legs, each wall is sandwiched between a second leg and a leg extending from the first surface.  
     
     
         25 . A burner as recited in  claim 24  wherein the plurality of second legs intersect each other.  
     
     
         26 . A method for forming a closed burner comprising: 
 introducing a pan having a base and surrounding walls;    introducing a ceramic board having a first surface opposite a second surface and a peripheral edge there between;    attaching at least a metallic strip to the peripheral edge;    covering the second surface, and edge with a foil; and    attaching the foil to the walls exposing the first surface of the ceramic board forming a closed burner.    
     
     
         27 . A method as recited in  claim 26  wherein the step attaching comprises the step of welding the at least one strip to the walls.  
     
     
         28 . A method as recited in  claim 26  wherein the foil is made from aluminum.  
     
     
         29 . A method as recited in  claim 26  wherein the step of attaching comprises bonding the foil the walls using an adhesive.  
     
     
         30 . A method as recite in  claim 26  further comprising the step of carving the first surface of the board.  
     
     
         31 . A method as recited in  claim 26  wherein the step of introducing a ceramic board and the surrounding steps comprises: 
 shaping a foil in the shape complementary of the desired board second surface and peripheral edge;  
 placing the at least one metal strip within the foil pan along the surface of the foil complementary to the peripheral edge;  
 pouring a ceramic material in the foil pan; and  
 baking the foil with at least one strip and ceramic material forming a ceramic board having a shape complementary to the foil and having the at least one metallic strip adjacent to its peripheral edge, and the at least one strip and the second surface of the board surrounded by the foil.  
 
     
     
         32 . A method for forming a closed burner comprising: 
 introducing a pan having a base and surrounding walls;    introducing a ceramic board having a first surface opposite a second surface and a peripheral edge there between;    covering the second surface and edge with sheet metal; and    attaching the foil to the walls exposing the first surface of the ceramic board forming a closed burner.    
     
     
         33 . A method as recited in  claim 32  wherein the step  7  attaching comprises the step of welding the sheet metal to the walls.  
     
     
         34 . A method as recited in  claim 32  wherein the step of attaching comprises gluing the sheet metal to the walls using an adhesive.  
     
     
         35 . A method as recited in  claim 32  further comprising forming holes in the sheet metal adjacent the second surface for defining gas outlets.  
     
     
         36 . A method as recited in  claim 32  further comprising the step of carving the first surface of the ceramic board.  
     
     
         37 . A method as recited in  claim 32  wherein the step of introducing a ceramic board and the surrounding steps comprise: 
 shaping a the sheet metal in the shape complementary of the desired board second surface and peripheral edge;  
 pouring a ceramic material in the shaped sheet metal; and  
 baking the shaped sheet metal with the ceramic material forming a ceramic board having a shape complementary to the shaped sheet metal and having its peripheral edge and the second surface of the board surrounded by the foil.  
 
     
     
         38 . A burner comprising: 
 a concrete board having a thickness and ports defined there through; and    a pan comprising a peripheral surface, wherein a portion of the peripheral surface is embedded in the concrete board, wherein the concrete board and pan define an enclosed burner and wherein the concrete defines an exposed surface of the burner.    
     
     
         39 . A burner as recited in  claim 38  further comprising a ceramic board embedded in the concrete board.  
     
     
         40 . A burner as recited in  claim 38  wherein the ceramic board comprises ports aligned with ports formed on the concrete board.  
     
     
         41 . A burner comprising: 
 a refractory board comprising a refractory adhesive; and    a pan comprising a peripheral surface, wherein a portion of the peripheral surface is embedded in the refractory board, wherein the refractory board and pan define an enclosed burner and wherein the refractory board defines an exposed surface of the burner.    
     
     
         42 . A burner as recited in  claim 41  further comprising a ceramic board embedded in the refractory board.  
     
     
         43 . A burner as recited in  claim 41  wherein the ceramic board comprises ports aligned with ports formed on the refractory board.  
     
     
         44 . A method for making a burner comprising the steps of: 
 providing a mold having an inner surface having a desired shape;    pouring a refractory material in the mold;    providing a burner pan comprising a peripheral surface;    embedding the peripheral surface of the pan in the refractory material;    curing the refractory material forming an enclosed burner; and    removing the mold.    
     
     
         45 . A method as recited in  claim 44  wherein the step of providing comprises providing a mold having at least a protrusion extending to a level, and wherein the step of pouring comprises pouring the refractory material to a level lower than the level of the protrusion.  
     
     
         46 . A method as recited in  claim 45  wherein the step of pouring comprises pouring concrete.  
     
     
         47 . A method a recited in  claim 45  wherein the step of pouring comprises pouring a refractory adhesive.  
     
     
         48 . A method as recited in  claim 45  further comprising the steps of: 
 providing a ceramic board having at least a port;  
 placing the ceramic board into the mold such that the port is penetrated by the protrusion prior to the step of pouring.