Modular assembly for electric fireplace

Abstract

An electric fireplace (410) includes a fireplace housing (412) and a heater assembly (426) that is configured to generate heated air. The heater assembly (426) is configured to be installed substantially within the fireplace housing (412). The heater assembly (426) includes a heater body (445), a first grill cover (448) that is selectively couplable to the heater body (445), and a second grill cover (548) that is alternatively selectively couplable to the heater body (445). The first grill cover (448) has a first cover length (468), and the second grill cover (548) has a second cover length (568) that is different than the first cover length (468). The heater assembly (426) is selectively positionable within a cabinet (311) having a structural opening (311A), and a center shelf (360) that defines at least a portion of an upper side (311U) of the structural opening (311A). The heater assembly (426) is installed substantially adjacent to the center shelf (360).

1 - 20 . (canceled) 
     
     
         21 . A method for assembling an electric fireplace and cabinet assembly combination, the method comprising the steps of:
 providing a package assembly that retains (i) a cabinet assembly in an unassembled configuration, the cabinet assembly including a plurality of unassembled, cabinet structural components, and (ii) an electric fireplace in an unassembled configuration, the electric fireplace including a heater assembly that is configured to generate heated air, a flame generator that is configured to generate a simulated flame, and an electrical connection assembly, the electrical connection assembly including a low voltage cable assembly that selectively electrically connects the heater assembly to the flame generator;   assembling the cabinet structural components to define a structural opening within an assembled cabinet;   positioning the flame generator into the structural opening;   positioning the heater assembly into the structural opening independently of the flame generator; and   electrically connecting the flame generator to the heater assembly with the low voltage cable assembly.   
     
     
         22 . The method of  claim 21  wherein each of the cabinet assembly and the electric fireplace are selectively movable between the unassembled configuration and an assembled configuration; and wherein the package assembly, which is configured to retain the cabinet assembly and the electric fireplace when in the unassembled configuration, has a reduced form factor that is less than approximately 65% of a partially assembled form factor of the electric fireplace and the cabinet assembly when the electric fireplace is in the assembled configuration and the cabinet assembly is in the unassembled configuration. 
     
     
         23 . The method of  claim 21  wherein each of the cabinet assembly and the electric fireplace are selectively movable between the unassembled configuration and an assembled configuration; and wherein the cabinet assembly is moved to the assembled configuration prior to the electric fireplace being moved to the assembled configuration. 
     
     
         24 . The method of  claim 23  wherein the electric fireplace is moved from the unassembled configuration to the assembled configuration within the structural opening as defined by the cabinet assembly in the assembled configuration. 
     
     
         25 . The method of  claim 21  wherein the step of providing includes the electric fireplace further including a grate; and further comprising the step of positioning the grate into the structural opening contemporaneously with the flame generator. 
     
     
         26 . The method of  claim 25  wherein the step of providing includes the electric fireplace further including one or more simulated logs; and further comprising the step of positioning the one or more simulated logs substantially into the structural opening, the grate being configured to support the one or more simulated logs. 
     
     
         27 . The method of  claim 25  wherein the step of electrically connecting includes electrically connecting the flame generator to the heater assembly with the low voltage cable assembly by coupling one end of the low voltage cable assembly to the heater assembly and coupling the other end of the low voltage cable assembly to the grate. 
     
     
         28 . The method of  claim 21  wherein the step of providing includes the low voltage cable assembly including a low voltage DC cable. 
     
     
         29 . The method of  claim 21  wherein the step of providing includes the electrical connection assembly further including an electrical cable assembly that is configured to be electrically coupled at one end to the heater assembly, and electrically coupled at the other end to a power source. 
     
     
         30 . The method of  claim 29  wherein the step of providing includes the electrical cable assembly including an AC power cord. 
     
     
         31 . The method of  claim 21  further comprising the steps of coupling a controller including a processor to the heater assembly; and controlling operation of the heater assembly and the flame generator with the controller. 
     
     
         32 . A combination that is configured for receipt by a consumer, the combination comprising:
 a package assembly that retains (i) a cabinet assembly in an unassembled configuration, the cabinet assembly including a plurality of unassembled, cabinet structural components, the cabinet assembly being assemblable into an assembled configuration such that the cabinet structural components define a structural opening within an assembled cabinet, and (ii) an electric fireplace in an unassembled configuration, the electric fireplace including (a) a heater assembly that is configured to generate heated air, the heater assembly being positionable into the structural opening, (b) a flame generator that is configured to generate a simulated flame, the flame generator being positionable into the structural opening independently of the heater assembly, and (c) an electrical connection assembly including a low voltage cable assembly that selectively electrically connects the heater assembly to the flame generator.   
     
     
         33 . The combination of  claim 32  wherein the electric fireplace is selectively movable between the unassembled configuration and an assembled configuration; and wherein the package assembly, which is configured to retain the cabinet assembly and the electric fireplace when in the unassembled configuration, has a reduced form factor that is less than approximately 65% of a partially assembled form factor of the electric fireplace and the cabinet assembly when the electric fireplace is in the assembled configuration and the cabinet assembly is in the unassembled configuration. 
     
     
         34 . The combination of  claim 32  wherein each of the cabinet assembly and the electric fireplace are selectively movable between the unassembled configuration and an assembled configuration; wherein the cabinet assembly is configured to be assemblable into the assembled configuration prior to the electric fireplace being assembled into the assembled configuration; and wherein the electric fireplace is configured to be assemblable into the assembled configuration within the structural opening as defined by the cabinet assembly in the assembled configuration. 
     
     
         35 . The combination of  claim 32  wherein the electric fireplace further includes a grate that is positionable into the structural opening contemporaneously with the flame generator. 
     
     
         36 . The combination of  claim 35  wherein the electric fireplace further includes one or more simulated logs that are positionable substantially into the structural opening, the grate being configured to support the one or more simulated logs. 
     
     
         37 . The combination of  claim 35  wherein the low voltage cable assembly includes a low voltage DC cable that selectively electrically connects the heater assembly to the flame generator by coupling one end of the low voltage DC cable to the heater assembly and coupling the other end of the low voltage DC cable to the grate. 
     
     
         38 . The combination of  claim 32  wherein the electrical connection assembly further includes an electrical cable assembly that is configured to be electrically coupled at one end to the heater assembly, and electrically coupled at the other end to a power source, the electrical cable assembly including an AC power cord. 
     
     
         39 . The combination of  claim 32  wherein the electric fireplace further includes a controller including a processor that is coupled to the heater assembly, the controller being configured to control operation of the heater assembly and the flame generator. 
     
     
         40 . A method for assembling an electric fireplace and cabinet assembly combination, the method comprising the steps of:
 providing a package assembly that retains (i) a cabinet assembly in an unassembled configuration, the cabinet assembly including a plurality of unassembled, cabinet structural components, and (ii) an electric fireplace in an unassembled configuration, the electric fireplace including (a) a heater assembly that is configured to generate heated air, (b) a flame generator that is configured to generate a simulated flame, (c) a grate, and (d) an electrical connection assembly, the electrical connection assembly including a low voltage cable assembly that selectively electrically connects the heater assembly to the flame generator, and an electrical cable assembly that selectively electrically connects the heater assembly to a power source;   assembling the cabinet structural components from the unassembled configuration into an assembled configuration to define a structural opening within an assembled cabinet;   subsequently assembling the electric fireplace from the unassembled configuration into an assembled configuration including positioning the flame generator and the grate contemporaneously into the structural opening, and positioning the heater assembly into the structural opening independently of the flame generator;   electrically connecting the flame generator to the heater assembly with the low voltage cable assembly by coupling one end of the low voltage cable assembly to the heater assembly and coupling the other end of the low voltage cable assembly to the grate; and   electrically connecting the heater assembly to the power source by coupling one end of the electrical cable assembly to the heater assembly, and coupling the other end of the electrical cable assembly to the power source.