Burner-log element

Abstract

Method of forming artificial logs made of an inorganic fiber material using compression molding are described. One method includes providing a molding composition comprising inorganic fiber and an inorganic binder, compression molding the molding composition into an artificial log, and providing a passageway that is defined by the artificial log and at least one burner aperture that is also defined by the artificial log to pass combustible gas to an outer surface of the artificial log. Artificial log elements and burner structures made by the use of such methods and a molding composition for use in compression molding are also described.

We claim:  
     
         1 . A method of forming an artificial log, the method comprising the steps of: 
 providing a molding composition comprising an inorganic fiber and an inorganic binder;    compression molding the molding composition into the artificial log; and    providing a gas passageway defined by the artificial log and at least one burner aperture defined by the artificial log to pass combustible gas to an outer surface of the artificial log.    
     
     
         2 . The method of  claim 1 , further comprising the step of coupling a hollow tube member to the artificial log.  
     
     
         3 . The method of  claim 1 , wherein the molding composition comprises an inorganic fiber, an inorganic binder, and a carrier solvent.  
     
     
         4 . The method of  claim 3 , wherein the inorganic fibers are glass fibers, ceramic fibers, refractory fibers, refractory ceramic fibers, mineral fibers, or mixtures thereof.  
     
     
         5 . The method of  claim 3 , wherein the inorganic fiber comprises chopped fiber glass.  
     
     
         6 . The method of  claim 3 , wherein the inorganic binder comprises silica, sodium, calcium, and magnesium based binders, or mixtures thereof.  
     
     
         7 . The method of  claim 3 , wherein the inorganic binder comprises colloidal silica.  
     
     
         8 . The method of  claim 3 , wherein the carrier solvent comprises water.  
     
     
         9 . The method of  claim 1 , wherein the molding composition has a moisture content in the range of 20 to 35% by weight of the molding composition.  
     
     
         10 . The method of  claim 3 , wherein the molding composition has a moisture content in the range of 25 to 27% by weight of the molding composition.  
     
     
         11 . The method of  claim 1 , wherein the artificial log is an article for use in a fireplace assembly, a grill assembly, a campfire assembly, or a burner assembly.  
     
     
         12 . A method of forming an artificial log, the method comprising the steps of: 
 providing a molding composition comprising inorganic fibers and a binder;    compression molding the molding composition into the artificial log, wherein at least 75% by weight of the molded article is inorganic material; and    providing a passageway defined by the artificial log and at least one burner aperture defined by the artificial log to pass combustible gas to an outer surface of the artificial log.    
     
     
         13 . The method of  claim 12 , wherein at least 90% by weight of the artificial log is inorganic material.  
     
     
         14 . The method of  claim 12 , wherein at least 95% by weight of the artificial log is inorganic material.  
     
     
         15 . A method of forming an artificial log, the method comprising the steps of: 
 providing a molding composition comprising inorganic fibers and a binder;    compression molding the molding composition into the artificial log such that the binder transforms into a cured binder, wherein the cured binder is capable of withstanding temperatures of at least 600° F.; and    providing a passageway defined by the artificial log and at least one burner aperture defined by the artificial log to pass combustible gas to an outer surface of the artificial log.    
     
     
         16 . The method of  claim 15 , wherein the cured binder is capable of withstanding temperatures of at least 800° F.  
     
     
         17 . The method of  claim 15 , wherein the binder comprises an inorganic binder.  
     
     
         18 . A method of forming an artificial log, the method comprising: 
 providing a molding composition comprising inorganic fibers and a binder;    compression molding the molding composition into the artificial log, wherein the artificial log is capable of withstanding temperatures of at least 600° F.; and    providing a passageway defined by the artificial log and at least one burner aperture defined by the artificial log to pass combustible gas to an outer surface of the artificial log.    
     
     
         19 . The method of  claim 18 , wherein the artificial log is capable of withstanding temperatures of at least 800° F.  
     
     
         20 . The method of  claim 18 , wherein the binder comprises an inorganic binder.  
     
     
         21 . An artificial log made by the method of compression molding of  claim 1 .  
     
     
         22 . An artificial log made by the method of compression molding of  claim 12 .  
     
     
         23 . An artificial log made by the method of compression molding of  claim 15 .  
     
     
         24 . An artificial log made by the method of compression molding of  claim 18 .  
     
     
         25 . An artificial log comprising an inner surface defining a passageway in fluid communication with at least one burner aperture defined by the artificial log; and wherein the artificial log is compression molded.  
     
     
         26 . An artificial log comprising an outer surface, wherein the outer surface of the artificial log defines at least one burner aperture to provide combustible gas to the outer surface; and wherein the artificial log is compression molded.