True flush-mounted gas fireplace

Abstract

A manufactured fireplace is adapted for flush-mounting within a pre-sized opening in a wall structure without the need to double the layers of drywall surrounding the opening. The fireplace metal facing panels are manufactured to be flush from the fireplace window to an outer edge of the panels. Non-combustible board is attached over the panels during manufacture of the fireplace, obviating the need for installers to size, cut and attach non-combustible board to the fireplace panels on site then to attempt to achieve a flush-mounting by doubling up the layer of drywall surrounding the fireplace opening. The fireplace including the attached non-combustible board facing is shipped to a work site for installation.

1 . A pre-fabricated gas fireplace assembly for installation into a structure, comprising:
 a firebox;   a window for viewing the inside of said firebox;   a plurality of metal panels at least partly surrounding said window;   each of said panels being planar between an inner edge of each panel that is proximal to said window and an outer edge of said panel that is distal from said window, and including an outer portion for fastening said panel to a stud in a wall framework;   a layer of non-combustible board overlying and being attached to the surface of each of said panels to substantially cover said panel;   wherein the firebox, the panels and the non-combustible board define a pre-fabricated fireplace assembly prior to introduction into the structure.   
     
     
         2 . The pre-fabricated fireplace assembly of  claim 1  wherein at least one of said panels is disposed above said window and at least another of said panels is disposed along a side of said window. 
     
     
         3 . The pre-fabricated fireplace assembly of  claim 2  wherein said layer of non-combustible board attached to each of said panels comprises a single piece of non-combustible board covering all of said panels and defining an opening corresponding to said window. 
     
     
         4 . A method of using the pre-fabricated fireplace assembly of  claim 1  comprising the steps of:
 procuring delivery of said assembly to a work site; 
 removing said board from said metal panels; 
 fastening at least two of said metal panels to studs of a wood frame wall; 
 re-securing said board to said metal panels; and, 
 installing a single layer of drywall to said studs surrounding said fireplace such that the surface of said board is coplanar with the surface of said drywall. 
 
     
     
         5 . A method for installing a fireplace assembly into a structure, the method comprising the steps of:
 manufacturing a fireplace;   attaching non-combustible board to the facing panels of the fireplace during manufacture of the fireplace;   thereafter, shipping the fireplace assembly to an installation location; and,   installing the fireplace assembly within a pre-sized opening of the structure at the installation location.