Manufacture of simulated heritage windows

Information

  • Patent Grant
  • 6180196
  • Patent Number
    6,180,196
  • Date Filed
    Tuesday, November 17, 1998
    25 years ago
  • Date Issued
    Tuesday, January 30, 2001
    23 years ago
Abstract
Simulated heritage windows e.g. in the appearance of leaded or stained glass panels are made by applying strips of material such as plastic tape in predetermined patterns on registering surfaces of the sheets which make up a double or triple glaze window. The strips can be applied in any desired pattern, e.g. rectilinear or diamond shaped and are applied in an automated manner by tape dispensing heads that are moved over the glass surface in parallel. The production system includes a conveyor for transporting the glass sheets as well as a rotary suction cup which grips the sheets and enables its rotation through e.g. 90° when a second set of strips is to be applied at right angles to the first strip. The apparatus also includes a turntable by means of which the glass sheet can be flipped over or inverted when strips are to be applied to both of its sides.
Description




BACKGROUND OF THE INVENTION




1. Field of Invention




This invention relates generally to methods for the manufacture of multiple-pane sealed glazing units and more particularly of units that incorporate decorative features that simulate the appearance of leaded or stained glass panels, and also to units products by such methods.




2. Description of the Prior Art




In U.S. Pat. No. 5,494,715 issued to Glover, there is a description of the various efforts that have been made in recent years to improve the energy efficiency and condensation resistance of multiple-glazed sealed units. These improvements include: low-e coatings, argon or krypton gas fill, narrow width cavities and insulating spacing-and-desiccant systems for perimeter edge seals.




As noted in the U.S. Pat. No. 5,494,715, there is also a growing consumer interest in heritage window features with one popular feature being leaded or stained glass panels. Traditionally, these panels have been made by hand using grooved lead strips or cames. In the past because these handcrafted panels were very labor intensive to produce, various efforts have been made to simplify traditional production techniques and these efforts have been documented in the patent literature.




U.S. Pat. No. b


3


,


226


,


903


issued to Lillethun describes a triple-glazed sealed unit with a traditional stained-glass panel being incorporated as the center glass lite.




U.S. Pat. Nos. 4,335,170 and 4,438,165 issued to Butler describe a stained glass panel fabricated from a single glass pane where lead profiles are adhered in coincidental alignment to either side of a flat glass sheet. The extruded lead profiles are manually applied and are approximately 0.022 inches in thickness. Because of the stiffness and thickness of the lead profiles, the top lead profile has to be stretched and bent around the bottom lead profile and as a result, the process has to be carried out manually with each lead profile being individually applied.




U.S. Pat. No. 5,494,715 issued to Glover describes a triple pane unit with the center glass pane located only ⅛″ away from the front glass lite. To create the visual illusion of a solid lead came, three thin stripes are applied. One stripe is applied to the cavity face of the front glass sheet and the other two stripes are applied to either side of the center glass sheet. Traditional lead cames are grey in color, and if all three decorative stripes are colored grey, experience has shown that because of various optical and shadow effects, the visual illusion of a traditional leaded pane window is not always convincingly created.




For the triple stripe method described in U.S. Pat. No. 5,494,715, one key potential advantage is that the production process can be automated with the objective of producing over a 1000 decorative glass units per eight hour shift. However, the horizontal production equipment described involves glass sheets moving below a multi-head bridge assembly and no automated method or technique is given for applying the stripes to the opposite side of the glass.




SUMMARY OF THE INVENTION




The invention provides a method of applying decorative thin strips to a flat glazing sheet, said method comprising: applying a set of decorative thin strips on one side of a flat glazing surface; rotating said glazing sheet through a given angle and applying a second set of decorative thin strips at said given angle to first set of strips, said strips of the second set crossing and overlying said strips of the first set at points of intersection; wherein at least one of said sets of thin strips is applied in stages and each stage involves simultaneously applying two more thin strips.




The method may also include the further steps of flipping over the glass sheet and applying on the other side third and fourth sets of decorative thin strips in coincidental alignment with the thin strips of the first and second sets.




The given angle of intersection of the strips of different sets is chosen to suit the particular circumstances, e.g. at 90° where a rectilinear muntin bar appearance is to be achieved, or 60° where a diamond pattern is sought.




The strips can be applied with the glass sheet in a generally horizontal position, but preferably will be applied with the glass sheet in a generally upright position as providing a more convenient attitude in which the glass sheet can be flipped over or reversed, e.g. by the use of a turntable swivelling on a vertical axis, when the second side of the sheet is to be operated on.




The method described lends itself to automation through the use of air float/suction table surfaces to support the glass, and automatically guided and operated tape heads for applying tape to the glass to form the desired strip patterns.




From another aspect the invention provides a system of apparatus for carrying out the above discussed methods.




From another aspect the invention provides a sealed glazing unit that simulates the appearance of traditional metal came panels, said sealed glazing unit comprising: two or more parallel coextensive glazing sheets; peripheral seals extending continuously between the edges of said glazing sheets to define one or more glazing cavities between said sheets; decorative thin strips located on both flat surfaces of one of said glass sheets, said thin strips on respective surfaces being in mutually aligned registration with each other; wherein said decorative thin strips have one side that is of a relatively light shade and an opposite side that is of a relatively dark shade, said strips being attached to said glazing sheet in an orientation such that the side of relatively light shade is presented toward the adjacent exterior side of the glazing unit, whereas the side of relatively dark shade to is presented towards the interior side; wherein said strips are less than 0.005″ in thickness and arranged on each side of said one glass sheet in sets of parallel strips, said sets being arranged at a predetermined angle to each other to create a decorative grid pattern.




Where the strips are applied in the form of thin plastic strips with pressure sensitive adhesive securing them to the glass, then on each side of the glass the strips of one set overlap and overlie the strips of the other set at the points of intersection, the thickness of the strips being sufficiently small (less than 0.005″, and preferably about 0.002″) to enable this overlap to be accomplished without difficulty.




The plastic sheet material could conveniently be polyethylene terephthalate (PET), or the plastic tape could be made from a double lamination of plastic sheet material one side of which has a light shade and the other a dark shade. The light shade for example may simulate the appearance of lead or brass.




Alternatively the thin strips applied to the glass may be made of ceramic frit material which may be applied using heat release decals.











BRIEF DESCRIPTION OF THE DRAWINGS




The following is a description by way of example of certain embodiments of the present invention, reference being made in the accompanying drawings, in which:





FIG. 1

shows a fragmentary perspective view of a triple glazing unit that simulates the appearance of a leaded or stained glass window.





FIG. 2

shows an enlarged cross section detail of the triple glazing unit shown in FIG.


1


and featuring a double assembly of coated plastic film adhesive tapes on the center glass lite.





FIG. 3

shows an alternative cross section detail of the triple glazing is unit shown in FIG.


1


and featuring a double assembly of dual laminated plastic film adhesive tapes on the center glass lite.





FIG. 4

shows an alternative cross section detail of a double glazed glazing unit featuring a double assembly of dual-tone ceramic frit material on a single glass pane.





FIG. 5

shows plan views of the production steps for horizontal application of decorative adhesive tapes to one side of a glass sheet that is intended to be the center sheet of a stained or leaded glass panel.





FIG. 6

shows elevational views of the production steps for vertical application of decorative adhesive tapes to create a rectangular grid pattern.





FIG. 7

shows elevational views of the production steps for vertical application of decorative adhesive tapes to create a diamond grid pattern.





FIG. 8

shows a partial perspective view of an automated glass flipping station.





FIG. 9

shows plan views of the production steps for automated glass flipping.











DESCRIPTION OF THE PREFERRED EMBODIMENTS





FIG. 1

shows a fragmentary perspective view of a triple glazing unit that simulates the appearance of a leaded or stained glass window. The glazing unit


20


, consists of three glazing sheets; an inner glazing sheet


21


, an outer glazing sheet


23


, and a center glazing sheet


22


. A vertical strip


25


of adhesive tape material


24


is applied to the inner surface


26


of said center glazing sheet


22


.




To create a grid pattern, horizontal strips


28


and


29


are applied at right angles to the vertical strip


25


. At the intersection points


33


and


34


between the vertical and horizontal stripes, the horizontal stripes


28


and


29


are simply laid on top of the vertical stripe


25


.




The adhesive tape material is typically made from a plastic sheet material with a pre-applied pressure sensitive adhesive. One preferred material option for the plastic sheet material is polyethylene terephthalate (PET) and one preferred material option for the pressure sensitive adhesive is acrylic.




The outer surface


30


of the tape is a relatively light shade while the inner adhesive surface


31


of the tape which contacts the glass is a relatively dark shade. For simulated leaded glass panels, the lighter shade is typically grey while the darker shade is black. For simulated brass came panels, the light shade is typically a metallized brass finish while the darker shade is black.




For ease of application, and so that there is no need to bend or stretch the tape at the intersection points


33


and


34


, the sheet material should be less than 0.005″ in thickness and preferably less than 0.002″ in thickness.




A second vertical strip


35


is applied to the outer surface


27


of the center glass sheet


22


. The second strip


35


is in coincidental alignment with the first strip


25


. Similarly, a second set of horizontal strips


34


and


32


are applied to the outer surface


27


of the center glass sheet. This second set of horizontal stripes are also in coincidental alignment with the first set.





FIG. 2

shows a cross section detail of a triple glazed unit


20


featuring a double assembly of coated plastic film adhesive tapes


37


and


36


on the center glass sheet


22


. The adhesive tapes are made from black PET sheet film material


38


with a pre-applied pressure sensitive acrylic adhesive


39


. The black PET features a UV stable, metallized coating


40


, with a shiny brass appearance.





FIG. 3

shows an alternative cross section detail of a triple-glazed unit


20


featuring a double assembly of dual-laminated plastic film adhesive tapes


41


and


42


on the center glass sheet


22


. The adhesive tapes


41


and


42


are made from a dual-lamination of PET sheet film material


43


and


44


and with a pre-applied pressure sensitive adhesive


39


. The PET film


43


adjacent to the glass sheet is typically colored black while the outer sheet


44


is a grey or yellow brass colored PET.





FIG. 4

shows a cross section detail of a double glazed unit that simulates the appearance of a leaded or stained glass window. The glazing unit


45


consists of two glazing sheets, an inner glazing sheet


21


and an outer glazing sheet


23


. Thin strips of ceramic material


46


are applied to either side of the inner glazing sheet. The ceramic material is a dark shade on the bottom surface


47


adjacent to said glazing sheet and a light shade on the top surface


48


.




The thin strips of ceramic material can be produced either by applying continuous strips of heat release decal transfers to create a grid pattern or by applying large heat release ceramic decals on either side of the glazing sheet


21


.




The large size decals incorporate a metal came design and may also incorporate decorative colored areas to simulate the appearance of traditional stained glass windows. After the decal transfers have been applied, the glass sheet is heated to a high temperature and the ceramic material is fused into the glass surface creating a very durable finish that does not degrade or color fade over time.





FIG. 5

shows plans views of the production steps for the horizontal application of decorative adhesive tapes


27


to one side of a center glazing sheet


23


that is stationary.




The first step is to transfer a glazing sheet


23


to a horizontal tape application table


50


. Key features of the tape application table include: a linear motion system


51


, two or more tape heads


52


,


53


and an air float/suction surface


54


. The linear motion system


51


consists of a moveable rigid beam


55


that spans between a side activator


56


and a side guide rail


57


. The moveable rigid beam


55


incorporates a positioning rail


65


that allows the tape heads to be accurately positioned either by automated or manual means. The air float surface


54


is activated by a hip bar


58


operation and the glazing sheet


23


is moved into position and held against a popup stop


59


. Again through a hip bar


58


operation, the air flow for the air float surface


54


is reversed and the glass sheet


23


is held firmly in position through air suction.




By means of a foot pedal operation


60


, the linear motion system


51


is activated and the rigid beam


55


moves forward from its home position. Through optical sensors (not shown), the top edge


61


of the glazing sheet


23


is identified.




The tape heads


52


and


53


are then automatically activated and start to apply tape strips


62


at a specified distance from the top edge of the glass. As the rigid beam


55


, moves across the glazing sheet


23


, two or more adhesive tape strips are applied (See Step


2


).




The bottom edge


63


of the glazing sheet


23


is identified again by means of optical sensors and the tape heads


52


and


53


are automatically deactivated at a specified distance from the bottom edge


63


of the glass sheet


23


. The moveable rigid beam


55


then automatically stops in position in front of the operator


64


. From computer-generated instructions, the operator


64


repositions the tape heads


52


and


53


using either automated or manual means (See Step


3


). Through a foot pedal operation


60


, the moveable beam


55


is then activated and moves back to its original home position


65


. Depending on the complexity of the grid pattern, the process is again repeated and a further one or more strips are applied to the glazing sheet


23


.




When all the strips


62


have been applied in one direction, the air float surface


54


is activated to release the suction and provide an air float and the glazing sheet


23


is rotated through 90° (See Step


4


). A series of strips


66


are then applied at right angles to the original set


62


(See Step


5


). After the second set of strips


65


have been applied (See Step


6


), the glazing sheet


23


is manually flipped and is again positioned against the pop-up stop


59


. A second grid pattern is then applied to the opposite side of the glazing sheet


23


and these strips are coincidentally aligned with the first grid pattern


67


.





FIG. 6

shows elevation views of the production steps for vertical application of decorative adhesive tapes


24


to create the rectangular grid pattern.




The first production step is to automatically transfer a clear glazing sheet


23


to a vertical tape application station


70


. Key features of the tape application station include: a linear motion system


51


, two or more tape heads


52


,


53


and


69


and a moveable rotating suction cup


71


. The linear motion system


51


consists of a moveable rigid beam


55


that spans between two side activators


56


. The moveable rigid beam


55


incorporates a positioning rail


58


that allows the tape heads


52


,


53


and


69


to be accurately positioned through automated means.




The air float surface


54


is automatically activated and a glazing sheet


23


is automatically transferred by means of a motorized wheel track system


72


. Through a system of electronic controls and sensors, the glazing sheet


23


is centrally positioned on a moveable rotating suction cup


71


. The wheel track system


72


is retracted and the suction cup


71


is automatically activated moving the glazing sheet


21


to a reference location


73


(See Step


2


). The air flow to the air float surface


54


is deactivated and the glass sheet


23


is held firmly in position through both air suction and the moveable suction cup


71


.




The linear motion system


51


is then activated and the rigid beam


55


moves across the glazing sheet automatically applying two or more adhesive strips


62


to the glazing sheet


23


(See Step


3


). As with horizontal tape application, the process is repeated until all the strips have been applied in one direction. The air float surface


54


is then activated and the glazing sheet


23


rotated through 90° by means of the moveable suction cup


71


. (See Step


4


). A second set of strips


66


is then applied at right angles to the first set of strips


62


(See Step


5


). The glass sheet


23


is again rotated so that the longest glass side is perpendicular to the moveable beam


55


and the glass sheet


23


is then repositioned on the wheel track system


72


.





FIG. 7

shows elevation views of the production steps for vertical tape application of decorative adhesive tapes to create a diamond grid pattern. As with the production of rectangular grids, the glazing sheet


23


is centered on a moveable suction cup


71


. The suction cup


71


is moved upwards to a reference location and the glass sheet


23


is rotated and positioned at a given angle to the moveable beam


55


. The air float surface


54


is deactivated and the glass sheet is firmly held in place by means of both air suction and the moveable suction cup


71


. The linear motion system is then activated and the rigid beam


55


moves across the glazing sheet automatically applying two or more adhesive strips


62


to the glazing sheet


23


. The process is repeated until all the strips have been applied in one direction.




The air float surface


54


is then activated and the glazing sheet is rotated through a given angle by means of the moveable suction cup


71


. A second set of stripes


66


are then applied at a given angle to first set of strips


62


. The glass sheet


21


is again rotated so that the longest glass side


73


is perpendicular to the moveable beam


55


and the glass sheet is repositioned on the wheel track system


72


.





FIG. 8

shows an elevation view of an automated vertical glass flipping station


75


that is used in combination with the automated vertical tape application station


70


.




After the first adhesive tape grid pattern


67


has been applied to one side of the glazing sheet, the glass sheet is then flipped over prior to application of a second tape grid pattern that is aligned with the first grid pattern.




One way of flipping over the glazing sheet is by means of an automated glass flipping station


75


that is similar in function to a traditional steam train turntable. Key features of the automated glass flipping station include: a transfer slot


77


, air floatisuction surfaces


78


and


79


on either side of the transfer slot


77


, a reversible wheel track system


81


and a motorized turn table


82


.





FIG. 9

shows plan views of the production steps for automated glass flipping. A glass sheet


23


is transferred to the slot


77


within the automated glass flipping station


75


by means of the motorized wheel track system


81


. Once fully enclosed within the slot


77


, the glass sheet


21


is automatically stopped. The air float surface on the slot face


78


is reversed and the glass sheet is firmly held in position by means of suction. The automated glass flipping station is turned through 180° about a vertical axis until the slot


77


is once more accurately aligned with the wheel track system


72


. The suction is slot face


78


is reversed and the drive direction of the wheel track system


81


is also reversed.




The glass sheet


23


exits the slot


77


and proceeds to a second automated tape application station


70


where a second adhesive tape grid is applied in coincidental alignment with the first grid pattern but on the opposite surface of the glass sheet.



Claims
  • 1. A sealed glazing unit that simulates the appearance of traditional metal came panels, said sealed glazing unit comprising:two or more spaced apart parallel co-extensive glazing sheets; at least one peripheral seal extending continuously between edges of said glazing sheets to define at least one glazing cavity between said glazing sheets; at least one pair of decorative thin strips respectively located on opposing surfaces of one of said glazing sheets, said pair of decorative thin strips being in mutually aligned registration with each other; wherein each of said pair of decorative thin strips has an inward face and an outward face, such that said inward faces of said pair of decorative thin strips face toward each other and said outward faces of said pair of decorative thin strips face away from each other toward an exterior of said glazing unit; wherein said outward faces of said pair of decorative thin strips are of a relatively light shade and said inward faces of said pair of decorative thin strips are of a relatively dark shade which is darker than said relatively light shade; and wherein each of said pair of decorative thin strips is less than 0.005 inches in thickness.
  • 2. The sealed unit of claim 1, whereinsaid at least one pair of decorative thin strips comprises at least two pair of the decorative thin strips, said pairs of the decorative thin strips being arranged in parallel to one another.
  • 3. The sealed unit of claim 1, whereinsaid at least one pair of decorative thin strips comprises at least two pair of the decorative thin strips which are arranged at predetermined angles to each other to create a decorative grid pattern.
  • 4. The sealed unit of claim 1, whereinsaid at least one pair of decorative thin strips comprises at least two pairs of the decorative thin strips arranged in crossing relation to each other; and the strips of one of said pairs of the decorative thin strips overlie the strips of another of said pairs of the decorative thin strips at points of intersection therewith.
  • 5. The sealed unit of claim 1 wherein said decorative thin strips are formed of a material adhered to said one of said glazing sheets with a pre-applied pressure sensitive adhesive, and said one of said glazing sheets comprises a center glazing sheet of a triple glazed unit.
  • 6. The sealed unit of claim 5 wherein said pressure sensitive adhesive is an acrylic adhesive.
  • 7. The sealed unit of claim 5 wherein said decorative thin strips are made from plastic sheet material.
  • 8. The sealed unit of claim 7 wherein said plastic sheet material is made from polyethylene terephthalate (PET).
  • 9. The sealed unit of claim 7 wherein each of said decorative thin strips is made from a double lamination of plastic sheet material.
  • 10. The sealed unit of claim 7 wherein each of said decorative thin strips is made from a plastic film with an applied light shade coating.
  • 11. The sealed unit of claim 10 wherein said light shade coating gives the appearance of lead.
  • 12. The sealed unit of claim 10 wherein said light shade coating gives the appearance of brass.
  • 13. The sealed unit of claim 1 wherein said thin strips are made from ceramic frit material.
  • 14. The sealed unit of claim 7 wherein said ceramic frit material is applied using heat release decals.
US Referenced Citations (8)
Number Name Date Kind
3226903 Lillethun Jan 1966
3420730 Ellefson Jan 1969
4154880 Drennan May 1979
4335170 Butler Jun 1982
4438165 Butler Mar 1984
4488919 Butler Dec 1984
4495739 Drennan Jan 1985
5494715 Glover Feb 1996
Foreign Referenced Citations (2)
Number Date Country
1000698 Jan 1961 GB
2140348 May 1984 GB