The formation of glass into useful and artistic objects dates to at least the 4th Century BCE. Among the established techniques for forming glass are flow-molding, press-molding and hand-blowing. Hand-blown glass objects are admired for the artistry and skill required to produce them, and the uniqueness of each piece so produced. One effect traditionally produced by glass-blowing artisans is the inclusion of decorative cracks in finished products. The inclusion of such features signifies artistry, skill and uniqueness. However, the very nature of the hand-blowing process renders hand-blown pieces expensive and impractical for use as containers for all but the highest-end products such as fine perfumes and select alcoholic beverages.
Contrasting with the artistry associated with hand-blown glass objects is the rapid mass production of strictly utilitarian objects such as window panes and beverage bottles. Among the goals of manufacturing vessels such as drinking glasses and beverage bottles are rapid reproducibility and uniformity of appearance among units. Of particular importance is uniformity among units in physical dimensions such opening shape and size in order to facilitate the use of standardized lids, plugs or caps as closures. Accordingly, in the modern era, glass vessels are largely produced by strictly-controlled automated hot pressing and blowing processes. Such processes have the advantage of being relatively inexpensive and invariant, but result in products lacking uniqueness and artistry.
Accordingly, a need exists for a method of incorporating, within a glass object, and particularly a glass vessel, the unique feature of decorative cracks in a manner that facilitates ready and reliable reproducibility of predetermined physical dimensions.
Implementations of the present invention are generally directed to a method of mass-producing consistently-dimensioned cracked-glass vessels incorporating decorative cracks while maintaining structural integrity. Although not so limited in scope, among the glass vessels of particular interest are drinking glasses, cups, bowls, decanters, vases, and selectively closeable bottles.
In accordance with an illustratively implemented method, an initial gob of molten glass is gathered. In a typical version, the molten-glass gob is removed from a glass furnace by gathering it about a distal end of an elongated gathering implement such as a rod, tube or gathering iron, by way of example. The molten-glass gob is introduced into a pre-form mold into which—in one implementation—a quantity of gas, such as air, by way of non-limiting example, is injected in order to form the gob into a pre-form vessel having at least one pre-form vessel wall defining a pre-form vessel exterior surface and a pre-form vessel interior surface defining a pre-form vessel cavity. The quantity of gas blown into the pre-form mold depends, in part, on the desired wall and base thicknesses of the vessel being formed. In various illustrative implementations, depending on the size and shape of the vessel being formed, the pre-form vessel remains in the pre-form mold for a period of between 2 and 5 seconds before it is removed and transferred for subsequent processing.
In one version, when the pre-form vessel is sufficiently cool and “self-supporting” to retain its basic shape, it is removed, while still hot, from the pre-form mold, and a surface of the same is exposed to a fluid that is sufficiently cool, relative to the pre-form vessel, that cracks are formed along the surface exposed to the fluid. In any particular implementation, an appropriate temperature differential between the pre-form vessel and the rapid-cooling fluid is a function of the glass type, pre-form vessel wall thickness and the specific heat of the fluid in question. In each case, the aforesaid temperature differential should be sufficiently large in magnitude to introduce the desired cracks, but not so large that the pre-form vessel experiences thermal shock that either shatters the pre-form vessel or introduces cracks too deep into the pre-form vessel wall. In some illustrative implementations, the fluid to which the pre-form vessel is exposed in order to crack it is a liquid, such as water. However, absent express limitations to the contrary in the appended claims, it is to be understood that the rapid-cooling fluid may be a liquid other than water or even a gas. In one illustrative version in which a liquid is used, a liquid temperature of 26-deg. Celsius is regarded as optimal. Additionally, in alternative versions, the surface of the pre-form vessel that is exposed to the rapid-cooling fluid is the exterior surface.
In a first illustrative version in which the desired crack effects have been introduced, the pre-form vessel is reheated such that the glass becomes sufficiently flowable that (i) cracks are sealed between the pre-form interior and exterior surfaces and (ii) the pre-form vessel can be reshaped. The reheated pre-form vessel is introduced into a finish mold. A quantity of gas is injected into the finish mold in order to form the pre-form vessel into a finished vessel having at least one finished vessel wall defining finished vessel interior and exterior surfaces between which cracks are visible and sealed. In a second illustrative version in which the desired crack effects have been introduced, the pre-form vessel is not reheated before finish molding. Instead, immediately after the introduction of cracks by exposure to a cooling fluid, the pre-form vessel is introduced into the finish mold where it is injected with air for a brief period of time (e.g., between 3 and 4 seconds). This finish molding step itself promotes the “sealing” of cracked areas internally from within the vessel, as long as the pre-form vessel is still sufficiently heated after cracking.
In some implementations, the pre-form and finish molds are actually the same physical mold which, when used in a “pre-forming” step is referred to as a “pre-form mold” and, when used in a “finish-molding” step is referred to as a “finish mold.” In fabricating a more complex glass vessel, such as a bottle including a neck, the use of physically distinct pre-form and finish molds facilitates intermediate shaping, thereby obviating logistical difficulties and diminished quality attendant to the use of a single mold at two different stages of the process in order to form of a shapeless gob into the final shape desired. Although the summation of the process to this point has implied molding in two stages, it will be generally appreciated that implementations prescribing more than two molding steps are also within the scope of the invention as defined in the claims. More specifically, even in implementations involving three or more molding steps, at least one such step (e.g., the first molding step) is regarded as a pre-forming step involving a pre-form mold, while at least one other step (i.e., the final molding step) is regarded as a finish molding step involving a finish mold. In at least one implementation described later in the present specification, a finish mold is used in intermediate and final molding steps.
Irrespective of whether the pre-form vessel is re-heated prior to finish molding, alternative implementations of the process prescribe heating of the cracked and finish-molded vessel or “finished vessel.” More specifically, the finished vessel is removed from the finish mold and permitted to cool for a brief period of time, typically between 2 and 4 seconds, for example. The finished vessel is then heated in order to seal the cracks on the exterior surface of the vessel while taking care not to re-melt the glass and perceptibly deform the shape of the finished vessel. In an illustrative implementation, the finished vessel is heated by a burner system in which burners torch the area of the vessel cracked by exposure to the cooling fluid. In various versions, the cracked regions are torched for between 3 and 6 seconds. However, as with the other time ranges presented as examples, this latter range should not be regarded as limiting the scope of the inventive process absent express limitations to the contrary in the claims appended hereto.
In alternative implementations, apparatus controlled by a programmable computer are variously utilized in the performance one or more steps. For instance, the use of a computer-controlled pneumatic injector is particularly useful in ensuring that the quantity and pressure of gas injected into the mold is appropriate, precise and selectively tunable. Additionally, at least one multi-piece mold can be opened and closed by computer-controlled pneumatics, hydraulics or motor-actuated linkages. While human involvement is integral to the implementation of some versions, particularly at the gob-gathering, cracking and heating stages—where an artisan's vision and skill might be desired—in alternative versions, even one or more of the steps prior to introduction of the gob into either the pre-form mold, or the introduction of the pre-form vessel into the finish mold, is performed by computer-controlled apparatus.
Representative, non-limiting implementations are more completely described and depicted in the following detailed description and the accompanying drawings.
The following description of methods of fabricating a glass vessel with decorative cracks is demonstrative in nature and is not intended to limit the invention or its application of uses. The various implementations, aspects, versions and embodiments described in the summary and detailed description are in the nature of non-limiting examples falling within the scope of the appended claims and do not serve to maximally define the scope of the claims.
In conjunction with
The illustrative implementations described with reference to
With continued reference to
When the pre-form vessel 50 is sufficiently cool and “self-supporting” to retain its basic shape, the pre-form mold 30 is opened and the pre-form vessel 50 is removed, as shown in, respectively,
Referring to
With continued reference to
With reference to
After sealing in the finish mold 70, the pre-form vessel 50 has been transformed into what is regarded as a “finished vessel” It will be appreciated, particularly in implementations involving more than two “molding” stages, that the designation of a work-piece as either a “pre-form vessel” or a “finished vessel” can be somewhat arbitrary. This is particularly the case when, for example, a finish mold (e.g., finish mold 70) is used in more than one step since the final basic shape is imparted to the vessel prior to the final “molding” step. However, in an effort to lend a measure of clarity to the description, a vessel undergoing processing is regarded as a “pre-from vessel” up until the point that is treated for the last time in a mold. More specifically, upon introduction into a finish mold for the final time, a vessel is referred to as a “pre-form vessel” and, upon removal from that mold for the last time, it is regarded as a “finished vessel.”
An example of a finished vessel 80 is shown in
Referring to
A second illustrative version tracks the initial steps of the first illustrative version described above in conjunction with
Following the introduction of cracks 58 along at least one pre-form wall 52, in a first implementation in which the non-finally-shaped pre-form vessel 50 is cracked, the pre-form vessel 50 is reheated in order to (i) fuseably seal the cracks 58 under a continuous “skin” of glass between the pre-form interior and exterior surfaces 56 and 54 and (ii) render the pre-form vessel 50 sufficiently soft for additional shaping. It will be appreciated that the reheating of the pre-form vessel 50 involves a balance of mutually competitive objectives. In accordance with one set of objectives, the pre-form vessel 50 is heated sufficiently to facilitate “sealing over” of the cracks 58 and refined shaping. However, a second set of objectives indicates that the pre-form vessel 50 not be heated to such an extent that the cracks 58 are lost through complete re-fusion of glass through the entire thickness of the pre-form wall 52 or such that the pre-form vessel 50 loses too much of its shape. In a second implementation in which the non-finally-shaped pre-form vessel 50 is cracked, the vessel 50 is not re-heated prior to subsequent processing. It will be appreciated, however, that the pre-form vessel 50 must still be sufficiently hot for final shaping in general accordance with the steps described below. In illustrative cases in which the pre-form vessel 50 is reheated, it is introduced into a furnace, such as furnace 15 in
Irrespective of whether the cracks 58 are sealed over by re-heating, the cracked and non-finally-shaped pre-form vessel 50, while still sufficiently heated for shape refinement, is situated within a finish mold 70. As with the finish mold 70 of
As previously explained, alternative implementations involve the use of either (i) a single mold in temporarily separate “pre-forming” and “finish-molding” steps or (ii) two or more physically distinct molds in “pre-forming” and “finish-molding” steps. As a general observation, more intricate final products call for molding in at least two stages with at least two physically distinct molds. For instance, while the formation of a vessel such as a drinking cup might be pre-formed and finish molded in a single physical mold, a vessel such as a bottle might call for physically distinct pre-form and a finish molds. The illustrative finished vessels 80 of
The foregoing is considered to be illustrative of the principles of the invention. Furthermore, since modifications and changes to various aspects and implementations will occur to those skilled in the art without departing from the scope and spirit of the invention, it is to be understood that the foregoing does not limit the invention as expressed in the appended claims to the exact constructions, implementations and versions shown and described.
Number | Date | Country | Kind |
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MX/E/2010/048025 | Aug 2010 | MX | national |
Priority based on Provisional Application Ser. No. 61/571,647 filed Jul. 2, 2011, and entitled “METHOD OF FABRICATING DECORATIVELY-CRACKED GLASS OBJECTS” is claimed. Priority is also claimed in Mexican Patent Aplication Folio No. MX/E/2010/048025 filed Aug. 4, 2010 and entitled ELABORACION DE BOTELLAS DE VIDRIO Y CRISTAL POR MEDIO DE LA TECNICA DE CRAQUELADO. The entirety of the disclosures of each of the previous applications, including the drawings, is incorporated herein by reference as if set forth fully in the present application.
Number | Date | Country | |
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61571647 | Jul 2011 | US |