US 20060046017 A1
A decorative architectural glass panel comprises a two or more glass sheets separated by a resin in which one or more decorative objects are suspended. A method of making the glass panel comprises positioning one or more spacers and one or more decorative objects on a first glass sheet, placing a second glass sheet about the first glass sheet, sealing the edges of the first glass sheet and second glass sheet, and filling the space between the first and second glass sheets with a curable liquid resin. The resin can be poured using a substantially horizontal pour in order to keep the decorative objects from substantially shifting when pouring the liquid resin. The resin can also be poured in combination with a vacuum force. In some implementations, the glass panel may also be substituted with a resin panel using polymeric resin sheets.
1. A decorative architectural panel comprising:
a first glass sheet positioned opposed to a second glass sheet in a registered fashion; and
plurality of decorative objects suspended in a cured resin between the first and second glass sheets.
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9. A sheet assembly for use in creating a decorative architectural panel comprising:
a first sheet comprising one or more spacers positioned on a surface thereof;
one or more decorative objects positioned on the first sheet surface;
a second sheet overlaid with the first sheet in a registered fashion, such that the one or more decorative objects are positioned throughout an interspace region defined by the first and second sheets;
blocking means positioned about a peripheral edge of the sheet assembly;
a sealant positioned about the blocking means; and
a liquid resin poured between the first sheet and the second sheet, wherein the liquid resin comprises a layer between the first sheet and the second sheet that is at least one-eighth inch thick when cured.
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a third and fourth glass sheet positioned opposed to the first or second glass sheets in a registered fashion; and
one or more second decorative objects suspended in a curable resin between the third and fourth glass sheets.
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a third sheet and a fourth sheet overlaid with any of the first or second sheet in a registered fashion; and
one or more second decorative objects positioned between the third and fourth sheets, and encapsulated by the liquid resin;
wherein the one or more decorative objects comprise a first object layer, and the one or more second decorative objects comprise a second object layer.
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The present invention claims the benefit of priority to U.S. Provisional Patent Application No. 60/606,364, filed on Sep. 1, 2004, entitled “Architectural Glass Panels with Embedded Objects and Methods for Making the Same”, the entire contents of which are incorporated herein by reference.
1. The Field of the Invention
The present invention relates generally to decorative glass and resin products and processes, for use in architectural design and construction.
2. Background and Relevant Art
Recent architectural designs have focused on decorative panels, such as glass or polymeric resin panels, which can be used in a wide variety of environments in a wide variety of embodiments, such as decorative windows, and as partitions in offices and homes, and so forth. In general, suitable architectural polymeric resin materials (or, “resins”) for use in decorative panels comprise polyvinyl chloride, acrylic, poly(methylmethacrylate) or “PMMA”, poly(ethylene-co-cyclohexane 1,4-dimethanol terephthalate) or “PETG”, as well as related polycarbonates.
Glass and resin materials each have a number of unique advantages that make them respectively useful for certain applications. For example, polymeric resin materials tend to be more malleable, better suited for large-scale, decorative production techniques, and less expensive than conventional glass. Resin materials are also often used in a number of applications where the appearance of glass (e.g., translucence or transparence) or other properties of glass is desired.
Conventional glass also has its own set of properties that make it a unique decorative architectural material. For example, glass has a particular optical clarity and physical rigidity that is noticeably different from many conventional polymeric resins. By contrast with resin materials, however, glass cannot ordinarily be heated and pressed using conventional thermosetting processes to include decorative objects or patterns. In particular, decorative glass tends to crack or blemish at many of the conventional temperatures and pressures that are otherwise used to set multiple resin sheets together into a single panel.
As such, one method for making a conventional, decorative glass panel comprises placing two glass sheets at opposing sides of a relatively thin decorative object, placing relatively thin two-sided tape around the peripheral edges between the two opposing glass sheets, and inserting a curable resin between the glass sheets. To pour the resin, the manufacturer perforates the tape, and pours the curable resin from top to bottom, as the glass sheets are held in an upright, vertical position. This vertical position helps the liquid resin follow the pull of gravity, and flow easily throughout the cavity between the two glass sheets. At the same time, the vertical position helps any air bubbles between the two sheets float toward the top of the pour.
Unfortunately, this method of pouring liquid resin in a vertical direction is fairly limited to thinly-spaced, opposing glass sheets (e.g., the thickness of the two-sided tape) that can be pressed against relatively flat decorative objects (e.g., the thickness of the two-sided tape, or less). That is, the vertical pour method relies in part on decorative objects that will not move when the glass sheets are held in an upright position. For example, just as any air bubbles tend to float to the top when the manufacturer pours the liquid resin in a vertical pour, the decorative object between the opposing glass sheets may slide to the bottom if it is not tightly held, or float upward on top of the resin. This may prohibit a manufacturer from attempting to suspend unevenly-sized decorative objects between opposing glass sheets.
By contrast, horizontally pouring the resin into the cavity between the opposing glass sheets, rather than pouring vertically, can create other difficulties that make conventional glass difficult to use. For example, rather than positioning the two glass sheets upright, the manufacturer may simply pour the curable liquid resin between the glass sheets as they lay flat on a support surface. Unfortunately, this horizontal position makes it difficult to adequately distribute the liquid resin throughout the space between the two opposing glass sheets evenly.
Furthermore, air bubbles are likely to be trapped between the opposing glass sheets during a horizontal pour, rather than float away to one side or another. Combined with the relatively high cost of glass, imperfections resulting from imperfect pours, or trapped air bubbles, make horizontal pours relatively impractical for large-scale manufacturing purposes. Thus, conventional glass panels are limited to being relatively thin, or having relatively thin, evenly-sized decorations included inside.
Accordingly, an advantage in the art can be realized with methods and apparatus that allow a manufacturer to create decorative glass panels that avoid one or more of the foregoing problems in the art. In particular, an advantage in the art can be realized with methods and apparatus that allow a manufacturer to include a wide variety of decorative objects, beyond simply flat, evenly-sized patterns, between opposing glass sheets.
The present invention solves one or more of the foregoing problems in the prior art with methods and apparatus for creating decorative architectural glass panels that include any type of decorative objects embedded inside. In particular, implementations of the present invention include positioning two or more glass sheets together about one or more decorative objects, and then inserting a curable resin using a substantially horizontal pour.
In one implementation, a manufacturer lays a first glass sheet against a support surface, and then places one or more spacers about the periphery of the first glass sheet. The manufacturer then arranges one or more decorative objects on the first glass sheet between the spacers, and registers a second glass sheet over the first glass sheet. Thereafter, the manufacturer positions blocking means about the periphery of the first and second glass sheet, such that the blocking means do not prohibit removal of the one or more spacers. The manufacturer can then apply a viscous sealant, such as a silicone or urethane-based sealant, about the periphery of the first and second glass sheets.
When the first and second glass sheets are blocked and sealed appropriately, the manufacturer can create one or more pores in the sealant, and then pour the curable resin through the one or more pores in a substantially horizontal fashion. This pouring method can ensure that the decorative objects to not move substantially out of an initial position, and can ensure that air bubbles are not trapped between the glass plates. After removing any lingering air bubbles, the glass sheet assembly is then left to cure into a final product.
Additional features and advantages of exemplary implementations of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of such implementations. The features and advantages of such implementations may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features will become more fully apparent from the following description and appended claims, or may be learned by the practice of such exemplary implementations as set forth hereinafter.
In order to describe the manner in which the above-recited and other advantages and features of the invention can be obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
The present invention extends to methods and apparatus for creating decorative architectural glass panels that include any type of decorative objects embedded inside. In particular, implementations of the present invention include positioning two or more glass sheets together about one or more decorative objects, and then inserting a curable resin using a substantially horizontal pour.
In some cases, such as if synthetically formed, the decorative objects 105 may appear substantially two-dimensional, such as in the case of silk leaves, silk flowers, naturally-occurring grasses, and the like. In other cases, the dimensions of the decorative objects will be such that they readily appear as three-dimensional objects, such as with crushed rocks, thatch reed, branches or twigs, and the like. Nevertheless, it will be appreciated that essentially all decorative objects will have at least some three-dimensional aspect, despite some objects 105 being relatively flatter or thicker than others.
When preparing the glass panel 100, a manufacturer will typically begin by cleaning the glass sheets used to form the panel by removing any existing oils, such as residual oils. Oils such as these can ultimately contaminate the resins, or other matrix-forming materials, used inbetween the sheets, resulting in an inferior glass panel product. To clean or remove the potentially harmful residues, one suitable method (not shown) comprises scrubbing both sides of each glass sheet with a polishing abrasive, such as pumice. In one implementation, the manufacturer applies the polishing abrasive using water and steel wool. The manufacturer can then position the glass sheets to form glass panel 100, as described herein.
Once the first glass sheet 110 is in position, the manufacturer (i.e., operator, user, etc.) places one or more spacers 113 about its periphery. The spacers 113 are typically of a uniform size appropriate for the eventual size of the final glass panel 100, or for the size of the decorative objects 105. For example, a manufacturer can implement ½ inch tall spacers to make a thicker resin pour that will add bulk to the glass panel 100. Alternatively, the manufacturer can implement ⅛ inch tall spacers to suspend decorative objects that are no larger than 1/10 of an inch in any dimension. In other implementations, rather than discrete, individual spacers, a manufacturer may include a tape (or other adhesive) of an appropriate thickness about the periphery, and between the first and second glass sheets.
After spacing the glass sheets,
One way to overcome such potential detrimental effects is to apply an effective amount of preserving resin, such as placing a UV-curable resin about the organic decorative objects 105 before placing them on the first glass sheet 110. In general, a preserving resin, such as a UV-curable resin, essentially “seals” the organic material from discoloration. The UV-curable resin can also seal the organic material from evacuating moisture, since the sealant creates a barrier between the organic material and the catalyst of the resin (i.e., resin 140,
To apply the UV-curable resin in one implementation, the manufacturer dilutes the resin, and sprays it about the organic materials (i.e., decorative object 105) in a thin coat. The manufacturer then places the sprayed organic materials in a UV environment for a time sufficient to cure the resin (i.e., from a few minutes to about an hour), or until the organic materials are at least “tack-free”. After the UV-curable resin has cured an appropriate amount of time about the decorative objects 105, the manufacturer then positions the decorative objects 105 on the first glass sheet 110. (For purposes of this implementation, a suitable resin includes ASTROCURE, a resin made by ZIRCON, although other resins may be suitable for use within the context of the present invention.)
As shown in
When the manufacturer has appropriately prepared or aligned the relevant glass sheets 110, 120, spacers 113, and decorative objects 105 for each one or more layer of the glass sheet assembly 130, the manufacturer can position blocking means 125 about the plate assembly 130 periphery. Generally, the blocking means 125 comprise any means capable of providing a barrier between the resin (e.g., 140,
Referring now to
In any event, the sealant 135 provides an additional layer to prevent leakage of the resin 140, which is used to adhere the sheet assembly 130, as it is poured. The manufacturer then allows the glass sheet assembly 130 to set until the sealant 135 is at least “tack-free” to the touch. This setting period can take as much as about 24 hours, depending on the type of sealant 135 used.
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Alternatively, the manufacturer can place a tube or syringe on an opposing side of the glass sheet assembly 130 compared with the side in which the funnel 138 is positioned, in order to provide a vacuum force. In this implementation, the resin 140 flows through the funnel more quickly, due to the suction of the opposing syringe or tube. Furthermore, there is not necessarily any tilting of the glass sheet assembly 130, since the vacuum force may eliminate the need for gravitational flow in some cases. An implementation such as this may be useful in some cases where mass-production is desired, and where the glass sheet assembly 130 is very large.
In any event, notwithstanding any tilting, some air bubbles may still exist that must be removed before the resin 140 has fully cured. As shown in
One will appreciate that the apparatus and methods described herein can also be applied to a wide variety of glass panel 100 designs. For example, the manufacture can implement complex geometric patterns, such as curved glass sheets, by stacking the reciprocating patterns of the curved glass sheets together. The manufacturer can also modify the glass panel design with variations in the number or type of decorative items suspended in the resin 140. For example, the manufacturer may use synthetic materials, such as synthetic or silk leaves, orange slices, and so forth, in place of otherwise-naturally-occurring items.
The manufacture may also implement additional glass sheets in the sheet assembly 130, which allows the manufacturer to use as many as 2 or 3 more decorative object 150 layers. For example, a first decorative layer may comprise colored two-dimensional squares, a second decorative layer may comprise organic leaves, and a third decorative layer may comprise coffee beans. Accordingly, the inventive concepts described herein can be applied to several types of decorative architectural panels and designs.
In another implementation, the glass sheets 110 and 120 can be replaced with two or more resin sheets that comprise texturing on one or both sides. This may be useful when replacing glass sheets, since the textured surface of a given resin sheet can be lost in conventional thermosetting process. As such, a manufacturer may choose to use a first resin sheet having a textured surface on one side or both sides, a layer of resin and decorative objects as described herein, and a second resin sheet having a textured surface on an opposing one or more sides. Such a resin panel accordingly comprises one or more decorative objects in a resin panel having texturing on opposing sides.
In still a further implementation, the manufacturer may substitute any of the foregoing glass sheets 110, 120, etc. with relatively flexible glass sheets. As such, when a shrinking resin 140 begins to cure, the flexible glass sheets will bend toward each other, around the decorative objects 105 that have been placed inside. This can provide still further architectural options in accordance with the present invention.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.