# US 2010/0043282 A1 · Method and Device For Use of Hollow Spheres In A Composite Material > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2010/0043282 A1 - Document ID: US20100043282A1 - Status: Published application - Kind: A1 - Application number: 12/543,416 - Filed: 2009-08-18 - Published: 2010-02-25 - Earliest claimed: 2008-08-18 - Assignees: Forestwood Industrial, Inc. - Inventors: Jonathan Fischer - Web page: https://patentgrep.com/patent/US20100043282A1 ## CPC - C10L 11/02: based on refractory porous bodies - B28B 7/007: {with moulding surfaces simulating natural effets, e.g. wood or stone} - B28B 23/0087: {Lightweight aggregates for making lightweight articles} - C04B 28/02: containing hydraulic cements other than calcium sulfates - C10L 5/365: {Logs} - F24C 3/006: {simulating flames} - C10L: FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G OR C10K; LIQUIFIED PETROLEUM GAS; USE OF ADDITIVES TO FUELS OR FIRES; FIRE-LIGHTERS - B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B) - C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE - F24C: DOMESTIC STOVES OR RANGES (exclusively for solid fuels F24B); DETAILS OF DOMESTIC STOVES OR RANGES, OF GENERAL APPLICATION ## Abstract A non-combustible, synthetic fire-log is disclosed comprising a composition formed to approximate the shape of a combustible object, wherein said composition comprises a substantially non-combustible matrix and an effective amount of hollow spheres. In one embodiment, the effective amount of hollow spheres ranges from approximately 3 to 85 percent of the total composition by weight. The composition enhances the aesthetic quality of the synthetic fire-log when exposed to heat and also decreases the carbon monoxide emissions of synthetic fire-log systems. ## Claims ### Claim 1 A decorative, non-combustible synthetic fire-log, comprising: a composition formed to approximate the shape of a combustible object, wherein said composition comprises a substantially non-combustible matrix and an effective amount of hollow spheres, and wherein the effective amount of hollow spheres ranges from approximately 3 to 30 percent of the total composition by weight. ### Claim 2 (depends on 1) The decorative, non-combustible, synthetic fire-log of claim 1, wherein the substantially non-combustible matrix comprises concrete. ### Claim 3 (depends on 1) The decorative, non-combustible, synthetic fire-log of claim 1, wherein the substantially non-combustible matrix comprises ceramic fiber articles. ### Claim 4 A substantially non-combustible, synthetic fire-log material and gas fireplace assembly, comprising: a housing configured to receive a substantially non-combustible, synthetic fire-log material; at least one substantially non-combustible, synthetic fire-log material comprising a composition of a non-combustible matrix and an effective amount of hollow spheres; and a fuel source operably connected to the housing and configured to supply fuel to the housing. ### Claim 5 (depends on 4) The substantially non-combustible, synthetic fire-log and gas fireplace assembly of claim 4, wherein the effective amount of hollow ceramic spheres ranges from approximately 3 to 30 percent of the total composition by weight. ### Claim 6 (depends on 4) The substantially non-combustible, synthetic fire-log and gas fireplace assembly of claim 4, wherein the effective amount of hollow ceramic spheres ranges from approximately 30 to 45 percent of the total composition by weight. ### Claim 7 (depends on 4) The substantially non-combustible, synthetic fire-log and gas fireplace assembly of claim 4, wherein the effective amount of hollow ceramic spheres ranges from approximately 45 to 85 percent of the total composition by weight. ### Claim 8 (depends on 4) The substantially non-combustible, synthetic fire-log and gas fireplace assembly of claim 4, further comprising a synthetic fire-log having a first surface and a second surface, wherein the distribution of the effective amount of hollow spheres on the first surface is different than the distribution of the effective amount of hollow spheres on the second surface. ### Claim 9 (depends on 4) The substantially non-combustible, synthetic fire-log and gas fireplace assembly of claim 4, wherein the distribution of the effective amount of hollow spheres throughout the composition is variable. ### Claim 10 (depends on 4) The substantially non-combustible, synthetic fire-log and gas fireplace assembly of claim 4, wherein the distribution of the effective amount of hollow spheres throughout the composition is substantially fixed. ### Claim 11 A substantially non-combustible, synthetic fire-log and gas fireplace assembly, comprising: a housing having at least a bottom member configured to receive a substantially non-combustible, synthetic fire-log; at least one substantially non-combustible, synthetic fire-log disposed about the bottom member of the housing, said synthetic fire-log comprising a non-combustible matrix and an effective amount of hollow ceramic spheres disposed on an outer surface of the substantially non-combustible, synthetic fire-log; and a fuel source operably connected to the housing and configured to supply fuel to the housing. ### Claim 12 (depends on 11) The substantially non-combustible, synthetic fire-log and gas fireplace assembly of claim 11, wherein the hollow ceramic spheres are adhered to an outer surface of the substantially non-combustible, synthetic fire-log. ### Claim 13 (depends on 12) The substantially non-combustible, synthetic fire-log and gas fireplace assembly of claim 12, wherein the hollow ceramic spheres are adhered to an outer surface of the substantially non-combustible, synthetic fire-log with a heat-resistant mastic. ### Claim 14 (depends on 11) The substantially non-combustible, synthetic fire-log and gas fireplace assembly of claim 11, wherein said hollow ceramic spheres are combined with a heat-resistant mastic to form a composition adhered to an outer surface of said synthetic fire-log. ### Claim 15 (depends on 11) The substantially non-combustible, synthetic fire-log and gas fireplace assembly of claim 11, wherein the hollow ceramic spheres are disposed on less than the entire surface of the synthetic fire-log. ### Claim 16 A method of manufacturing a non-combustible synthetic fire-log material assembly, comprising: providing a mold with an interior adapted to approximate the shape of a combustible object; placing a first composition comprising a substantially non-combustible matrix having an effective amount of hollow spheres within the mold; allowing the composition within the mold to harden; and removing the hardened composition from the mold. ### Claim 17 (depends on 16) The method of manufacturing a non-combustible synthetic fire-log material assembly of claim 16, wherein the interior of the mold is adapted to approximate the shape of a wood log. ### Claim 18 (depends on 16) The method of manufacturing a non-combustible synthetic fire-log material assembly of claim 16, wherein the effective amount of hollow spheres ranges from 3 to 18 percent of the total first composition by weight. ### Claim 19 (depends on 16) The method of manufacturing a non-combustible synthetic fire-log material assembly of claim 16, wherein the effective amount of hollow spheres ranges from 18 to 45 percent of the total first composition by weight. ### Claim 20 (depends on 16) The method of manufacturing a non-combustible synthetic fire-log material assembly of claim 16, further comprising placing a second composition comprising a substantially non-combustible matrix having an effective amount of hollow spheres within the mold, wherein the effective amount of hollow spheres within the second composition is different than the effective amount of hollow spheres within the first composition. ### Claim 21 (depends on 16) The method of manufacturing a non-combustible synthetic fire-log material assembly of claim 16, wherein the interior of the mold is adapted to approximate the shape of a piece of coal. ### Claim 22 (depends on 16) The method of manufacturing a non-combustible synthetic fire-log material assembly of claim 16, wherein the effective amount of hollow spheres ranges from 45 to 85 percent of the total first composition by weight.