U.S. patent number 3,619,456 [Application Number 04/810,742] was granted by the patent office on 1971-11-09 for simulated stained glass assembly and method of making the same.
Invention is credited to Charles L. Taylor, Jr..
United States Patent |
3,619,456 |
Taylor, Jr. |
November 9, 1971 |
SIMULATED STAINED GLASS ASSEMBLY AND METHOD OF MAKING THE SAME
Abstract
An assembly made from plastic which appears to be of stained
glass set in lead, and the assembly can be made in any design that
can be made by stained glass set in lead. The primary method for
making the assembly is to arrange horizontally grooved plastic
cames on a horizontal surface in the framework of the design
desired, then to fill the design with a filler material to the
bottom of the grooves, then to place variously colored liquid
plastics in the design to fill it to the top of the grooves, next
to cure the plastic, and finally to remove the filler material. In
one variation of the method, no filler material is used and the
liquid plastic fills the design from the bottom of the cames to the
top of the grooves. When this variation is used, the resulting
assembly appears to be stained glass set in lead only when viewed
from one side.
Inventors: |
Taylor, Jr.; Charles L. (Dixon,
IL) |
Family
ID: |
25204589 |
Appl.
No.: |
04/810,742 |
Filed: |
March 26, 1969 |
Current U.S.
Class: |
264/245; 264/250;
264/255; 428/38 |
Current CPC
Class: |
B29C
39/12 (20130101); B44F 1/063 (20130101) |
Current International
Class: |
B29C
39/12 (20060101); B44F 1/06 (20060101); B44F
1/00 (20060101); B29c 009/00 (); B44f 001/00 () |
Field of
Search: |
;156/245,63,248,289,344
;161/5,18,38,138 ;264/317,245,250,255 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Goolkasian; John T.
Assistant Examiner: Epstein; Henry F.
Claims
I claim:
1. A method of creating a simulated stained glass assembly
including the steps of
a. forming on a generally horizontal work surface a framework made
with thermoplastic members having horizontal grooves by heating the
members until the members become pliable and then bending them to
form a number of open sections within the outer limits of the
framework, the arrangement of said sections conforming to the
design of the assembly being created,
b. placing a sufficient quantity of a colored liquid plastic
material in each open section to fill that section to the tops of
the grooves, different colored plastic being placed in the
respective open sections to form the color scheme of the
design,
c. curing said liquid plastic whereby an assembly is made that has
the appearance of stained glass set in lead.
2. A method of creating a simulated stained glass set in lead
assembly comprising the steps of:
a. forming on a generally horizontal work surface a framework made
with plastic members having horizontal grooves, said framework
being arranged to form a number of open sections within the outer
limits of the framework, the arrangement of said sections being in
the design of the assembly,
b. filling said sections substantially to the bottoms of the
grooves with a filler material,
c. placing a sufficient quantity of colored liquid plastic material
on the filler material in each section to fill each section
substantially to the tops of the grooves, different colored plastic
material being placed in the respective open sections to form the
color scheme of the design,
d. curing said liquid plastic whereby panes of colored plastic are
formed in each section with the edge portion of each pane mounted
in the grooves of the framework surrounding that pane,
e. removing the filler material so that a plastic assembly is
created that has the appearance of a stained glass set in lead
assembly when viewed from any direction.
3. The method of claim 2 further characterized by the plastic
members being thermoplastic and the framework being formed by
heating the members until the members become pliable and then
bending them to conform to the design of the assembly being
created.
4. The method of claim 2 further characterized by the filler
material being wax, by heating the wax before placing it in the
sections, pouring it into the open sections, cooling the wax, the
plastic members being of a thermoplastic which remains rigid to a
higher temperature than the melting temperature of the wax and by
heating the assembly to the melting temperature of the wax after
curing the liquid plastic material, and then lifting the assembly
to allow the wax filler material to drain out of the assembly.
5. The method of claim 2 further characterized by mixing a catalyst
in the liquid plastic prior to placing the liquid plastic on the
filler material to cure the plastic after it is placed.
6. The method of claim 5 further characterized by painting an
artistic design on preselected panes after the catalyst has been
added to the liquid plastic but before the liquid plastic achieves
its final set.
7. The method of claim 2 further characterized by the work support
being transparent and by placing a pattern of the design below the
work support prior to forming the framework so that the pattern may
be used as a guide in making the assembly.
8. The method of claim 3 in which a heating element is associated
with the horizontal work surface to heat the work surface so as to
heat the plastic members.
9. The method of claim 4 in which a heating element is associated
with the horizontal work surface to heat the work surface and thus
to heat the assembly to melt the wax filler material so that the
wax can be drained out of the assembly.
Description
BACKGROUND OF THE INVENTION
In traditional stained glass assemblies such as windows, pieces of
different colored stained glass are arranged in a desired design.
The pieces of glass are mounted in grooved strips of lead called
cames, and the cames are fastened together and to a frame to
support and stabilize the assembly. Such stained glass assemblies
are extremely heavy and, because they are handmade, very expensive.
This invention relates to simulated stained glass assemblies made
of plastic and to the method of making such assemblies.
SUMMARY OF THE INVENTION
The general object of the present invention is to provide a new and
improved method for making a plastic assembly that appears to be
stained glass set in lead cames. An object of one aspect of the
invention is to provide a new and improved assembly made of plastic
and having the appearance of stained glass set in lead cames when
viewed from either face of the assembly. An object of a
modification of the invention is to provide a new and improved
assembly and method for making such an assembly which has the
appearance of stained glass set in lead cames only when viewed from
one face.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the upper portion of an assembly
embodying the novel features of the present invention.
FIG. 2 is a view similar to FIG. 1 but showing only the framework
of the assembly.
FIG. 3 is an enlarged perspective view of a portion of one of the
cames of the framework shown in FIG. 2.
FIG. 4 is a cross section taken substantially along the line 4--4
of FIG. 2 and showing the cames supported on a heatable work
surface.
FIG. 5 is an enlarged perspective view of a portion of one of the
edge cames making up the framework of FIG. 2.
FIG. 6 is a view similar to FIG. 4 but showing the filler material
in place.
FIG. 7 is a view similar to FIG. 6 but showing the liquid plastic
after it has been placed on the filler material.
FIG. 8 is a view similar to FIG. 7 but showing the filler material
being heated to aid in its removal.
FIG. 9 is a cross section taken substantially along the line 9--9
of FIG. 1.
FIG. 10 is a view similar to FIG. 9 but showing a second
embodiment.
FIG. 11 is an enlarged perspective view showing a welded joint
which joins two of the cames in the framework of FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In traditional stained glass assemblies, most commonly windows,
pieces of stained glass are arranged by color and shape to make a
particular desired design. Once the arrangement of the design is
set, the pieces of stained glass are mounted in grooved lead strips
called cames which separate the pieces and support them. These
cames are fastened together and to an outer frame to form a stable
framework in the desired design for the assembly. Such stained
glass assemblies are heavy, and because they are handmade, very
expensive.
The present invention contemplates a new and improved simulated
stained glass assembly 10 (FIG. 1) made of plastic and formed in
any desired design. Also contemplated by the present invention is a
new and improved method for making such an assembly. For these
purposes, grooved, lead appearing, plastic cames 11 and 11a (FIG.
2) are arranged as required to form the framework 12 (FIG. 2) of
any desired design. This framework divides the design into a number
of open sections 13 (FIG. 2) which are of the size and shape of the
various color requirements of the design. These sections are filled
by pieces, herein called panes 14 (FIG. 1), of colored plastic
which appear to be stained glass and which fill the sections in the
colors required by the design. A peripheral edge portion 15 (FIG.
9) of each pane is mounted in the grooves 16 (FIGS. 3 and 5) of the
cames which form the framework around that pane. To accomplish the
mounting of the panes 14 in the framework, liquid plastic material
of the appropriate color is poured into each section in such a
manner that, when the plastic material is cured, the panes are
formed with their edge portions in the grooves. With this
arrangement, a plastic assembly in any desired design can be made
and the assembly will appear to be stained glass set in lead cames.
Such an assembly can be made much more easily and at a great deal
less expense then a similar stained glass assembly.
As shown in FIG. 1, the assembly 10 is embodied in a window with an
abstract design. To make such a window, a transparent horizontal
work support 17 (FIG. 4) is used as a working surface to support
the assembly as it is being made. Spaced a short distance below the
work support is a second horizontal surface 18 so that a pattern 19
for the design of the assembly can be laid on the second surface
and viewed through the transparent work support by the person
making the assembly. To selectively heat the work surface, a series
of heating elements 20 (one being shown in FIGS. 4 and 8) is
located below the second surface.
After the design has been chosen and the pattern 19 for the design
has been placed on the second surface 18, an outer frame 21 (FIG.
2) for the assembly is formed of edge cames 11a (FIG. 5). In this
instance the edge cames are lengths of extruded plastic with a
rectangular cross section and a groove 16 along one vertical
surface 23. The edge cames are precolored to the appearance of lead
and they are made of an appropriate thermoplastic so that they are
rigid during the normal range of temperatures the assembly would be
subjected to. To make the assembly of FIG. 1, four edge cames of
the appropriate length are placed on the work surface 17 over the
outer edge lines of the design pattern 19 with the groove 16
extending horizontally and facing inward. The corners 24 (FIG. 2)
of the edge cames are then joined by plastic welding to create the
four sides of the framework 12. The framework of the assembly is
completed by inner cames 11 which, as shown in FIG. 3, are extruded
lengths of the same thermoplastic as the edge cames 11a and formed
with a rectangular cross section and a longitudinally extending
groove 16 positioned at the middle of the vertical surfaces 23 and
25. While the cames 11 and 11a are shown as rectangular in cross
section with their upper surfaces 26 and lower surfaces 27 (FIG. 3)
being flat, these surfaces can be of any desired configuration,
such as curved. The assembly has been described as rectangular but
the outer edges need not always be straight. The edge cames 11a may
be bent to give the assembly an outer edge that is round, curved or
any irregular shape.
The inner cames 11 are placed on the work surface 17, and it is
heated to a temperature sufficient to heat the inner cames to the
point at which they are pliable enough to be shaped. After being
heated, the inner cames are cut and shaped to form the remainder of
the framework 12 required by the pattern. This is accomplished by
following the pattern 19 seen through the transparent work support
to place the inner cames. When the framework is fully formed, the
ends 28 of the inner cames contact either another inner came or an
edge came 11a. The inner cames are welded at each point of contact
to one another or to an edge came (FIG. 11) to form the lead
appearing framework 12. After the inner cames cool, the welded
framework of inner cames and edge cames forms a rigid, stable
framework in the desired design. The placement of the cames in the
framework creates open sections 13 (FIG. 2) formed between the
cames and completely surrounded by inner cames 11 or a combination
of inner cames and edge cames 11a. These sections receive the
various colored panes 14 which simulate the stained glass portion
of the assembly 10.
To fill the sections 13 with the panes 14 (FIG. 1), a liquid
thermoplastic material is poured into the sections while the
framework 12 is lying on the work support 17, and the liquid
plastic is cured by applying either heat or a catalyst. Herein, a
catalyst is preferred. There are a number of liquid plastic
materials and catalysts commercially available, and they are well
known to those skilled in the art. The catalyst is mixed into the
liquid plastic prior to the liquid plastic being placed in the
sections 13. The liquid plastic material which is poured into each
section 13 is colored appropriately to meet the color requirements
of the design. Because of the color requirements of the design, the
individual panes may vary in transparency from being completely
transparent to being almost opaque. If any intricate or artistic
details are required on any pane 14, these details are painted on
while the plastic is being cured and is in the stage of curing just
before solidity is reached.
When it is desirable for the assembly 10 to have the appearance of
stained glass set in lead when viewed from any direction, such as
when used as a window, the plastic panes 14 should be of
approximately the same thickness as the grooves 16 in the cames so
that the vertical surfaces 23 and 25 of the cames will extend
beyond the faces of the panes (FIG. 9). To accomplish the above, a
filler material 30 (FIG. 6) is placed in the sections 13 before the
liquid plastic is placed in the sections. Herein, the filler
material is sealing wax but any suitable filler material, such as
foundry sand, can be used. With the framework 12 on the work
support 17, the wax heated to a liquid state is poured into the
sections in sufficient quantity to fill each section from the
bottom surface 27 of the cames 11 and 11a to the bottoms 31 of the
grooves 16 (FIG. 6). The top surface 32 (FIG. 6) of the wax is
finished smooth and flush with the bottoms of the grooves and then
the wax is allowed to cool and solidify. If it is necessary to keep
the wax liquid for any length of time, such as, to place it
properly and to finish the top surface, the heating elements 20 can
be used to heat the work support 17.
After the wax 30 has been placed, the liquid plastic is poured into
the sections 13 in sufficient quantity to fill each section from
the bottoms 31 to the tops 31a (FIGS. 3, 5 and 8) of the grooves
16. In this way, the plastic panes 14 are formed the same thickness
as the thickness of the grooves, and the peripheral edge portion 15
(FIG. 9) of each pane is formed in the grooves thus joining the
pane to the surrounding cames with a tongue-and-groove type
connection. The liquid plastic is cured and, after the curing is
complete, the wax 30 is removed. In this instance, the wax is
removed by heating the work support 17 to a temperature sufficient
to melt the wax and then lifting one end of the assembly 10 to
allow the wax to drain out. After the wax is removed, the assembly
10 is finished and ready for use. It is apparent that the framework
12 must be made of a thermoplastic that does not become pliable
until heated to a higher temperature than the melting point of the
wax.
When the assembly 10 will be seen from only one side, as when used
as an illuminated picture or a sign, only one side of the assembly
need give the appearance of stained glass set in lead. This is
important because from a cost standpoint it is less expensive to
make the assembly when only one side appears to be stained glass
set in lead. To accomplish this variation, no filler material is
used. The same basic method is followed as described above except
that no filler material is placed in the sections 13 prior to
pouring in the liquid plastic material to form the plastic panes
14. The liquid plastic material is poured into the sections in
sufficient quantity to fill each section from the bottom surfaces
27 of the cames which rests on the work support 12 to the tops 31a
of the grooves 16 (FIG. 10). In this way even though the overall
thickness of the pane is greater than the thickness of the grooves,
an edge portion 15a (FIG. 10) of the same thickness as the
thickness of the grooves 16 is formed around the periphery of each
pane. This edge portion joins each pane to the surrounding cames
with a tongue-and-groove type connection. In this variation the
lower face 33 (FIG. 10) of each pane is flush with the lower
surface 27 of the cames, and the upper face 34 of the pane is
recessed back from the upper surface 26 of the cames to give an
appearance of the stained glass set in lead only when viewed from
the recessed side.
It will be observed that the plastic assembly 10 is a lightweight,
inexpensive substitute for a stained glass set in lead assembly,
and the plastic assembly can be made so that it appears to be
stained glass set in lead when viewed from any side. When the
assembly is to be viewed from only one side, the assembly can be
made using a modified method for an even lower cost but with the
appearance of stained glass set in lead only when viewed from one
side. Likewise, it will be observed that the basic method and its
modification provide quick, simple, and inexpensive methods for
making the assemblies.
* * * * *