Fireplace surround system and method of making same

Abstract

A modular fireplace surround assembly for a fireplace opening is formed from a plurality of surround components comprising a first set of components, having a foam core and a manufactured stone veneer shell, located at least 8 inches from the fireplace opening, and a second set of components formed of entirely noncombustible materials including manufactured stone veneer. The first set of components are adapted to receive fasteners that pass through the back member for either direct or indirect mounting to the wall. In one embodiment, the first set of components includes a mantel shelf formed of interconnected, main and top components. The second set of components also establishes a front facing formed of a plurality of modular, interchangeable blocks arranged about the top and sides of the fireplace opening.

1 . A modular fireplace surround assembly mounted around a fireplace opening defined by top and side portions and being located in a wall above a floor, said modular assembly comprising:
 a plurality of surround components including a first set of components having a foam core and a manufactured stone veneer shell and being located at least 8 inches from the fireplace opening and a second set of components formed of entirely noncombustible materials including manufactured stone veneer and being mounted around the fireplace opening above the floor and including a front facing having a plurality of modular, interchangeable components arranged about the top and side portions of the fireplace opening, a first component of said second set of components having a lower end, an upper end, and a first groove located in the upper end receiving fasteners that pass through the first component into the wall and adapted to be covered by a second component of said plurality of surround components; and   a mantel shelf having a lower main body and an outer skin formed of a manufactured stone veneer, a reinforced back member receiving fasteners that pass through the reinforced back member into the wall, and a top component fitted onto the lower main body whereby, when the top component is installed, the top component creates a finished surface that conceals the fasteners.   
     
     
         2 . A fireplace surround assembly comprising:
 a plurality of surround components adapted to be mounted around a fireplace opening in a wall above a floor; and   a mantel shelf including:
 a lower main body; 
 a back member adapted to receive fasteners that pass through the back member into the wall; and 
 a top component adapted to fit onto the lower main body whereby, when the top component is installed, the top component creates a finished surface that conceals the fasteners. 
   
     
     
         3 . The fireplace assembly of  claim 2 , further comprising: a reinforcing member positioned against the back member within the lower main body. 
     
     
         4 . A fireplace surround assembly comprising:
 a plurality of surround components adapted to be mounted around a fireplace opening in a wall above a floor, said plurality of surround components including a first component and a second component, wherein the first component of said plurality of surround components having a lower end, an upper end and a first groove located in the upper end adapted to receive fasteners that pass through the first component for mounting the first component to the wall, and wherein the first component is covered by the second component of said plurality of surround components.   
     
     
         5 . The fireplace assembly of  claim 4 , wherein said first component is a leg member adapted to be mounted to extend vertically along the wall on one side of the fireplace opening. 
     
     
         6 . The fireplace assembly of  claim 5 , wherein the leg member has an outer skin formed of a manufactured stone veneer. 
     
     
         7 . The fireplace assembly of  claim 4 , wherein said first component is a corbel and the second component is a mantel shelf. 
     
     
         8 . The fireplace assembly of  claim 7 , wherein the corbel has an inner core formed of foam and an outer skin formed of a manufactured stone veneer. 
     
     
         9 . The fireplace assembly of  claim 4 , wherein said first component is a lintel and the second component is a mantel shelf. 
     
     
         10 . The fireplace assembly of  claim 9 , wherein the lintel has an inner core formed of foam and an outer skin formed of a manufactured stone veneer. 
     
     
         11 . A modular fireplace surround assembly mounted around a fireplace opening defined by top and side portions and being located in a wall above a floor, said modular assembly comprising:
 a plurality of components including first and second sets of components, each of the first set of components having a foam core and a manufactured stone veneer shell, with each of the first set of components being located at least 8 inches from the fireplace opening, each of the second set of components being formed of entirely noncombustible materials including manufactured stone veneer, with each of the second set of components being mounted around the fireplace opening.   
     
     
         12 . The modular fireplace surround of  claim 11 , wherein the first set of components includes a mantel shelf. 
     
     
         13 . The modular fireplace surround of  claim 12 , wherein the second set of components includes a front facing constituted by a plurality of modular, interchangeable components arranged about the top and side portions of the fireplace opening. 
     
     
         14 . The modular fireplace surround of  claim 13 , further comprising: a hearth member mounted on the floor below the fireplace opening, wherein the second set of components includes a pair of adjustable plinth stones mounted on the hearth member. 
     
     
         15 . The modular fireplace surround of  claim 13 , wherein the first set of components includes a pair of leg members extending vertically along the wall on opposite sides of the fireplace opening. 
     
     
         16 . The modular fireplace surround of  claim 13 , wherein the first set of components includes a pair of corbels adapted to be mounted below the mantel shelf. 
     
     
         17 . The modular fireplace surround of  claim 13 , wherein the first set of components includes a lintel member adapted to be mounted below the mantel shelf and across the fireplace opening. 
     
     
         18 . A method of forming a modular fireplace surround assembly around fireplace opening having top and side portions and being located in a wall above a floor comprising:
 selecting a first array of desired fireplace surround components from a first set of components having a manufactured stone veneer shell;   selecting a second array of desired fireplace surround components from a second set of components formed of entirely noncombustible materials including manufactured stone veneer;   temporarily mounting the first array of desired fireplace surround components around the fireplace opening through the use of mechanical fasteners;   permanently fixing the first array of desired fireplace surround components around the fireplace with an adhesive material; and   mounting the second array of desired fireplace surround components around the fireplace opening and between at least some of the first array of desired fireplace surround components.   
     
     
         19 . The method of mounting of  claim 18 , wherein temporarily mounting the first array of desired fireplace surround components includes:
 mounting a pair of leg members on the wall by passing at least one fastener into a groove in each leg member and into the wall;   mounting a lintel on the wall above the fireplace opening by passing fasteners into a groove in the lintel and into the wall; and   covering the grooves and fasteners with at least one of said first set of components.   
     
     
         20 . The method of mounting of  claim 18 , wherein mounting the second array of desired components comprises:
 mounting a hearth on the floor below the fireplace opening; and   installing a front facing, including a plurality of modular, interchangeable components each formed of an artificial stone veneer, by fixing the front facing in a desired pattern between the hearth and the first array of desired fireplace surround components.