Hearth panel apparatus for fireplace

Abstract

A hearth panel includes an edge member defining a geometric shape, such as a continuous loop, and two (or more) non-combustible panels with perimeters contained inside the edge member, and with the panels defining an air gap therebetween, thus providing an R value of over 2.0 and as high as 3.5 or more. Spacers in the air gap help prevent drooping of the panels. Tile is attached to the top panel for aesthetics. In some versions, the edge member includes a flange forming the gap's thickness. In some versions, the edge member is roll formed from constant thickness sheet, or extruded from an extrudable material such as aluminum.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows: 
     
         1 . A hearth panel comprising:
 an edge member defining a geometric shape;   at least two non-combustible panels with perimeters contained inside the edge member and that define an air gap therebetween; and   spacers in the air gap preventing drooping of a top one of the non-combustible panels.   
     
     
         2 . The hearth panel of  claim 1 , wherein the edge member includes a flange that spaces the at least two non-combustible panels apart, the flange having a thickness equal to the spacers. 
     
     
         3 . The hearth panel of  claim 2 , wherein edge member has an exterior surface that is non-planar and aesthetically shaped. 
     
     
         4 . The hearth panel of  claim 1 , including one of tile or stone on the top one of the non-combustible panels. 
     
     
         5 . The hearth panel of  claim 1 , wherein the geometric shape defines a continuous loop lying in a horizontal plane when in a use position. 
     
     
         6 . The hearth panel of  claim 1 , including an additional non-combustible panel forming an additional air gap with the first-mentioned non-combustible panels. 
     
     
         7 . A hearth panel comprising:
 an edge member having a cross section with a vertical flange and a horizontal flange;   two non-combustible panels inboard of the vertical flange and located on or under the horizontal flange and defining an air gap therebetween; and   spacers in the air gap preventing drooping of a top one of the panels.   
     
     
         8 . A hearth panel comprising:
 an edge member formed from a sheet having a constant width, the edge member having a cross section including a vertical flange and a horizontal flange connected to but spaced from the vertical flange by a connecting flange; and   at least one non-combustible panel with a perimeter bounded by the vertical flange.   
     
     
         9 . The hearth panel of  claim 8 , wherein the horizontal flange is notched at corners to facilitate forming the corners while preventing deformation when forming the corners. 
     
     
         10 . An edge apparatus for a hearth panel, the edge comprising:
 a profile formed from a sheet having a cross section including a first edge portion that extends upwardly, a first intermediate portion that extends outwardly and downwardly from a bottom of the first edge portion, a center portion that extends horizontally inwardly from a bottom of the first intermediate portion, a second intermediate portion that extends vertically upwardly from an inner edge of the center portion, and a second edge portion that extends horizontally inwardly from an upper edge of the second intermediate portion.   
     
     
         11 . The edge apparatus defined in  claim 10 , wherein the first intermediate portion extends outwardly and downwardly at an angle. 
     
     
         12 . The edge apparatus defined in  claim 10 , wherein the first and second edge portions do not touch each other but form an angle that is 90 to 95 degrees. 
     
     
         13 . The edge defined in  claim 10 , wherein at least one of the intermediate portion and second edge portion have two or more ribs increasing an air gap defined by the cross section and by an insultative panel attached to and supported by the profile. 
     
     
         14 . An edge for a hearth panel, the edge comprising:
 an edge member formed from a sheet having a constant-thickness and having a cross section including a first edge portion that extends upwardly, a center portion that extends horizontally inwardly, and a second edge portion that extends horizontally inwardly and that is spaced from the first edge portion;   the edge member having a length lying in a single plane and including at least four linear sections each joined by a sharp corner, each sharp corner being formed by one of bending and welding, where the corner formed by bending includes forming a notch at the corner so that when bent the length stays in the single plane, and where the corner formed by welding includes cutting an angle on abutting ends so that when welded the length maintains the cross section to and around the welded corner.   
     
     
         15 . An edge for a hearth panel, the edge comprising:
 an edge member formed from a sheet having a constant-thickness and having a cross section including a first edge portion that extends upwardly, a center portion that extends horizontally inwardly, and a second edge portion that extends horizontally inwardly and that is spaced from the first edge portion;   the edge member having a length lying in a single plane and including at least four linear sections each joined by a sharp corner, each sharp corner is formed by a corner bracket connecting adjacent ends of adjacent ones of the at least four linear sections.