Method of manufacturing a refractory panel for a fireplace

Abstract

A method of manufacturing a refractory panel. The method comprises forming a textured surface of interconnected subpanels. Adjacent ones of the sub-panels are partially separated from each other by gaps located between edges of the adjacent subpanels.

What is claimed is: 
     
         1 . A method of manufacturing a refractory panel, comprising:
 forming a textured surface of interconnected subpanels wherein adjacent ones of the sub-panels are partially separated from each other by gaps located between edges of the adjacent subpanels.   
     
     
         2 . The method of  claim 1 , wherein forming the textured surface of interconnected subpanels includes:
 forming hinges or welds between some of the edges of the subpanels.   
     
     
         3 . The method of  claim 1 , wherein forming the textured surface of subpanels includes:
 providing a single sheet of refractory material; and   cutting through the single panel to form the subpanels such that the subpanels remain connected to the single sheet on at least one side.   
     
     
         4 . The method of  claim 1 , further including bending the subpanels such that portions of the subpanels are out of an average plane of the refractory panel to thereby configure the textured surface as a three-dimensional textured surface. 
     
     
         5 . The method of  claim 4 , wherein the portions of the subpanels are bowed out in a direction perpendicular to the average plane of the refractory panel such that the bowed-out portions of adjacent ones of the subpanels are bowed out in opposite directions. 
     
     
         6 . The method of  claim 5 , wherein the bowed-out portions of adjacent ones of the subpanels form alternating concave and convex shaped surfaces with respect to a viewing location outside of the fireplace. 
     
     
         7 . The method of  claim 1 , wherein the average plane of the refractory panel is arched with respect to a viewing location outside of the fireplace. 
     
     
         8 . The method of  claim 1 , wherein the average plane of the refractory panel is planer with respect to a viewing location outside of the fireplace. 
     
     
         9 . The method of  claim 1 , wherein adjacent ones of each of the sub-panels are partially separated from each other by the gaps located between edges of each of the adjacent subpanels and the sub-panels are located within an outer perimeter of the refractory panel. 
     
     
         10 . The method of  claim 1 , wherein the gaps allow the passage of visible light through the planar or arched-shaped refractory panel. 
     
     
         11 . A method of manufacturing a refractory panel, comprising:
 forming a textured surface of interconnected subpanels wherein adjacent ones of each of the sub-panels are partially separated from each other by gaps located between edges of each of the adjacent subpanels and located within an outer perimeter of the planar or arched-shaped refractory panel, wherein the gaps allow the passage of visible light through the planar or arched-shaped refractory panel.   
     
     
         12 . A method of manufacturing a fireplace, comprising:
 forming walls to define an enclosed space and at least one opening;   locating a refractory assembly inside of the enclosed space the refractory assembly including a refractory panel, the refractory panel positioned such that a textured surface of the refractory panel can be viewed through the opening from outside of the fireplace, the refractory panel including:   interconnected sub-panels forming the textured surface, wherein adjacent ones of each of the sub-panels are partially separated from each other by gaps located between edges of each of the adjacent subpanels and located within an outer perimeter of the planar or arched-shaped refractory panel, wherein the gaps allow the passage of visible light through the planar or arched-shaped refractory panel.   
     
     
         13 . The method of  claim 12 , wherein locating the refractory assembly includes locating the refractory panel adjacent to one of the walls that is a rear wall. 
     
     
         14 . The method of  claim 12 , further including locating an illumination source behind the refractory panel and adjacent to one of the walls that is a rear wall. 
     
     
         15 . The method of  claim 14 , wherein the illumination source includes a low-BTU illumination burner. 
     
     
         16 . The method of  claim 12 , further including positioning a light reflecting panel behind the refractory panel and adjacent to one of the walls that is a rear wall. 
     
     
         17 . The method of  claim 16 , wherein a surface of the refractory panel that opposes the light reflecting panel includes a diffuse reflective finish or a translucent finish. 
     
     
         18 . The method of  claim 12 , further including locating an illumination source in front of the refractory panel.