GB2199609A

GB2199609A - Leaded lights

Info

Publication number: GB2199609A
Application number: GB08730284A
Authority: GB
Inventors: James Arthur Albert Hickman
Original assignee: Individual
Current assignee: Individual
Priority date: 1987-01-02
Filing date: 1987-12-30
Publication date: 1988-07-13
Anticipated expiration: 2007-12-30
Also published as: GB2199609B; GB8730284D0; GB8700024D0

Abstract

A glazing assembly comprises a glazing panel 40 laminated to a leaded glazing panel 6 having joining material 25 between the peripheral edges of adjacent glazing panes (7) and in which is embedded lead or other strips 11 on one or both faces. Panes 7 are temporarily held apart by tapes 21 while material 25 is inserted.

Description

Improvements in or relating to glazing assemblies This invention relates to a. glazing assembly of the kind comprising a first glazing panel laminated to a second glazing panel. In particular the invention relates to a glazing assembly in which the first glazing panel is a leaded or imitation leaded glazing panel comprising a number of joined together glazing panes. The invention also relates to a method of making a (leaded) glazing assembly of the kind referred to.

The construction of leaded or stained glass panels has traditionally been carried out using the same basic method for at least 100 years. This traditional method involves an artist initially setting out on paper, in full size, a basic diagram or pictorial representation of the leaded panel, the representation denoting the division and sizes of the glass panes, the colours of the glass panes and the precise position and paths for the H-section lead cames which retain the glass panes in position. The pictorial representation is laid vertically or horizontally over a light box and the glass panes are cut to size and laid over the pattern of the representat ion.Then the lead cames are cut to size and positioned around the various glass panes, each joint between adjacent lead came sections being soldered together to provide a framework of interconnected lead cames which extend along the joints between spaced apart peripheral edges of adjacent glazing panes. The partly formed panel is then laid flat and a proprietary leaded cement is brushed heavily over the entire frame, to force cement between the outside edges of the lead H-section cames and the glass panes. Once the cement has set, the leaded panel is given a final wash down and the leaded panel is finished. Some panels are fitted with metal tie bars to ensure rigidity when fixed in position or can be fitted with strengthening bars attached to the back of the lead cames in a manner which suits the leaded design.

A disadvantage of this traditional method is that it is time consuming, and thus costly, to produce lead panels in this manner. Furthermore the joints between the lead cames and the glass panes are not always properly sealed leading to problems if it is desired to laminate another glazing panel to the leaded panel.

The present invention seeks to provide a glazing assembly of the kind referred to which can be produced relatively quickly and cheaply and in which one of the glazing panels comprises a number of panes.

According to one aspect of the present invention a glazing assembly comprising a first glazing panel laminated to a second glazing panel, is characterised in that the first glazing panel comprises a number of glazing panes and joint means comprising joining material in the form of a binding and sealing compound or cement for joining confronting peripheral edges of adjacent glazing panes and sealing the glazing panes in a substantially liquid tight manner.

The joining material may comprise a setting or nonsetting compound or cement. A preferred joining material comprises silicone sealant material.

Preferably the said confronting peripheral edges are spaced apart, e.g. typically at least 4mm apart.

Strip portions may be arranged to cover at least one side of each joint between the said confronting peripheral edges of adjacent panes. These strip portions may be of any suitable material, e,g, plastic polycarbonate, rubber, PVC, aluminium, copper or other metals.

However lead is the preferred material since in this case all the joints between the various sections of lead may be soldered together and rubbed as is conventional in the traditional method of producing leaded glazing panels.

The strip portions may include an anchoring portion which is anchored in the joining material in gaps provided between spaced apart peripheral edges of adjacent glazing panes to retain the strip portions in position. Alternatively, or in addition, the strip portions may be adhered in position over each joint. In this latter case the strip portions may he self-adhesive or a separate adhesive may be employed.

According to a further aspect of the present invention there is provided a method of manufacturing a glazing assembly comprising laminating a first glazing panel to a second glazing panel, characterised in that the first glazing panel is made by arranging in a plane a number of glazing panes in interfitting relationship so as to define joints between confronting peripheral edges of adjacent glazing panes and joining the confronting peripheral edges of said adjacent glazing panes with joining material in the form of a binding and sealing compound or cement.

Conveniently. strip portions may be arranged to cover at least one side of each joint.

Conveniently the confronting peripheral edges of adjacent- glazing panes are spaced apart to define gaps therebetween and said glazing panes are positioned on top of temporary strips of flexible material which have been pre-arranged on a flat horizontal support surface along the course of said gaps. In this case the strips have a width greater than the gaps so as to close the bottom side of said gaps, the strips being subsequently removed after the gaps have been filled with said joining material. Preferably the strips are removed after arranging at least one support panel, on top of the partially formed glazing panel assembly (preferably after arranging said strip material over the upper side of said gaps) and turning the assembly through 1800 so that the glazing panes are supported on the support panel with said strips uppermost to enable their removal.Strip portions may then be arranged over the side of the gaps revealed by the removal of said strips. The turning of the glazing assembly is preferably achieved with the aid of a table having a top which is rotatable through at least 1800.

Embodiments of the invention will now be described.

by way of example, with reference to the accompanying schematic drawings, in which: Figure 1 is a sectional view through part of a conventional leaded glazing panel having glazing panes received in an H-section lead came; Figures 2, 3, 5, 6 and 9 are partial sectional views showing various stages in the manufacture of a laminated glazing assembly according to the invention having a leaded glazing panel, Figure 2 being shown on a smaller scale than Figures 3, 5, 6 and 9, Figure 4 is a partial sectional view showing an alternative embodiment for the partly assembled glazing panel shown in Figure 3, Figures 7 and 8 are partial sectional views showing two alternative embodimnents for the glazing panel shown in Figure 6 and Figure 10 illustrates an alternative step in the construction of a glazing assembly.

Figure 1 shows part of a conventional leaded glazing panel 1 having an H- or I-sect ion lead came 2 receiving in a loose fit the peripheral edge portions of two spaced apart glazing panes 3 and 4. Leaded cement 5 is brushed into the glazing pane/lead came joints. However the joints are not all together satisfactory since it is difficult to ensure air tightness of the joints. Furthermore difficulties arise in laminating such conventional leaded glazing panels because of the inflexible hold of the lead cames on the glazing panes which can result in cracking of the glazing panes during the laminating process.

Figure 6 shows part of one embodiment of a "leaded" glazing panel 6 of a glazing assembly of the invention.

The panel 6 comprises a number of, typically coloured, glazing panes 7 which are arranged in spaced apart, interengaging relationship to provide joints between confronting peripheral edges of adjacent glazing panes. The joints 9 are substantially liquid tight (at least to prevent outflow of liquid resin material during a subsequent laminating step with liquid resin material) and retain the panes in an assembled, interengaged relationship. (It will be appreciated that, in Figure 6, only two glazing panes 7 and one joint 9 are shown.) Each joint 9 comprises joining or filling material 10 in the form of a non-setting or setting binding and sealing compound or cement and covering lead strips 11 and 12 positioned on either side of the joint 9. Each lead strip 11, 12 has an anchoring portion lla, 12a, respectively, which is embedded in the filling material 10 to retain the strips 11, 12 in position. Typically the filling material comprises a silicone sealant material.

In Figure 6 the joint 9 shown provides a gap, typically from 4 - 10 mm wide, between peripheral edges of the panes 7. In other embodiments the "gap" may be smaller, the panes being joined together in the manner of a jigsaw, the various joints being sealed with joining material.

In order to manufacture the glazing panel 6, a full size paper design 15 (see Figure 2) in the form of a patterned and/or pictorial representation is positioned on top of a table 16. The design 15 is marked out to represent precisely the outlines of the various glazing panes 7 of the leaded panel 6 and of the joints 9 between the various panes 7. It is not essential for all the joints 9 to have the same width and different joint widths can be used to accentuate certain parts of the design.

The table 16 is internally illuminated by at least one light source 17 and has an upper support surface which is light transmitting so as to back illuminate the design 15 when the latter is positioned thereon. The top of the table 16 is also turnable about an at least substantially horizontal axis through at least 1800.

Once the design 15 is positioned on the table 16, a clear, transparent sheet 20 of glass is laid on top of the design 15. Strips 21 of tape material, which is slightly adhesive on one side and is non-adhesive on the other side, are carefully laid over the gaps on the design 15 between the panes 7 which, in the finished glazing panel are intended to provide the joints 9. The strips 21 are also laid around the entire outer periphery of the finished glazing panel design so as to be spaced slightly outwardly of the outer peripheral edges of the outermost pane designs. The strips 21 are laid in position with their slightly adhesive face adhering to the sheet 20. Ideally the tape material employed is of the type having a surface barrier which prevents adhesion thereto of sealant material such as silicone material.The tape material is chosen to have a width which is greater than the gaps between the glazing panes so that the strips 21 slightly overlap the- gaps when positioned on the sheet 20. By way of example, a strip width of 12 mm would be suitable for gaps having a width of up to 10 mm.

After the strips 21 have been positioned over all the joints 9 of the design 15, panes 7 of clear and/or coloured glass which have been cut to the correct size are carefully positioned over the design with their peripheral edges resting on the previously positioned strips 21. The panes 7 are temporarily held in position by blobs 22 of removable tacky adhesive material, such as plasticine or putty.

The gaps between the panes 7 are now in the form of channels 23, the sides of which are defined by the confronting peripheral edges of adjacent panes 7 and the bottoms of which are defined by the strips 21. These channels 23 are filled with filling material 25 in the form of a non-setting or setting binding and sealing compound or cement. Typically the filling material 25 comprises silicone sealing material which is suitably clear.

The upper sides of the filled channels 23 (i.e.

the sides opposite the strips 21) are now covered with covering strip material 11 (see Figure 3). In the construction of a leaded glazing panel, the strip material 11 will preferably be lead strip material, although imitation materials could be employed and, in theory, any desired pre-formed strip material, such as plastic polycarbonate, rubber, PVC, aluminium, copper or other metals, could be employed.

The strip material 11 has an offset anchoring portion lla which is inserted into the filling material 25 (before it sets in the case of a setting compound such as silicone) to anchor or retain the strip material in position.

It is not essential, however, for such an anchoring portion to be provided, and Figure 4 shows an alternative embodiment in which the strip material 26 is merely adhered in position, e.g. by the provision of an adhesive backing on the strip material, by the use of an adherent or by positioning the strip material in contact with a non-setting filling material 25. If an anchoring portion lla is employed it need not be offset. Around the peripheral edge of the glazing panel it is preferred to use strip material provided with such offset or central anchoring portions 1 Any joints between adjacent, e.g. abutting, sections of strip material 25 are suitably bonded or secured together at this stage.In the preferred case where lead strip material 25 is used, the lead is first primed and the joints are then soldered together and rubbed as in the traditional method of manufacturing leaded glazing panels. The partial glazing panel assembly is then cleaned with any surplus material being removed from joints or otherwise, and a second, cleaned clear pane 30 of glass of suitable size and thickness is then placed on top of the partial glazing panel assembly. A stiff board (not shown), typically 18 mm thick and made of wood, is then laid over the second glass pane 30. The whole assembly is then clamped together in a suitable manner and the top of the table 16 is rotated through 1800 so that the panel assembly is turned upside down.

The clamps are carefully removed and the board, now supporting the entire assembly, is removed downwards.

The table 16 is then revolved back to its original position and the board supporting the panel assembly is laid on top of the table 16. The panel assembly has now effectively been turned over through 1800. The design 15 and "top" panel 20 are removed exposing the taped joints (see Figure 5). Any strips 21 of the material not lifting with the glass panel 20 can be removed manually at this stage.

In order to finish the leading glazing panel 6, the upper sides of the "channels" 23 (i.e. the parts of the channel originally defined by the strips 21) are covered with further strip material 12 similar to the strip material 11. As with the previously applied strip material 11, the strip material may have an anchoring section 12a (see Figure 6). However this is not essential as depicted in the embodiment shown in Figure 7.

As a final assembly step, a further glazing panel 40 (see Figure 9) is laminated to the leaded glazing panel 6. In addition a further glazing panel (not shown) may be laminated to the other side of the leaded glazing panel 6. Because the glazing panel 6 is properly sealed all over and is more flexible than traditionally constructed lead panels, it can be laminated using traditional laminating techniques.However, it is preferred to use a pouring method involving any suitable settable liquid resin material, such method being described in detail in GB-B-2155856 or in my pending British Patent Application GB-A-2178363 (in which liquid resin material is introduced - e.g. hand poured or machine injected - between a leaded or stained panel and another glazing panel, the two panels being at least partly peripherally sealed with either gas-permeable or non-gas permeable tape or strip material sandwiched between the two panels).

Before laminating the glazing panel 6, all joints should be allowed to fully cure. Special glasses, e.g. diffuse reflection or non-reflective glass, may be laminated to one or both sides of the glazing panel 6. Any type of resin may be used for laminating although methacrylate resin is preferred. A glazing panel 6 which has been laminated may be incorporated in a multiple glazing unit such as a double glazing unit.

The construction of the leaded glazing panel 6 can be performed in a shorter time (typically up to half the time) than traditionally constructed leaded panels.

It also enables the lamination of leaded panels without many of the problems associated with the lamination of traditionally constructed leaded panels as set out in GB-A-2178363. The advantages of a laminated leaded panel are that cleaning is facilitated, the lead is protected and the entire panel is strengthened.

It is not essential for covering strip material 12 to be provided on the side of the joints which are to face inwardly. Such a glazing panel design having strip material on one side of a joint only is depicted prior to the lamination step in Figure 8.

There are several modifications which may be made to the method of construction described above. For example it is not necessary to employ the strips 21 of tape material. In this case a flexible sheet 20' of plastics material, e.g. polyethylene, (see Figure 10) is fixed, e.g.

pinned, in position over the design 15 in place of the previously described glass sheet 20. The clear and/or coloured glazing panes 7' are then laid on the sheet 20' in positions determined by the underlying design 15, the spaces or gaps left between the peripheral edges of adjacent panes 7' defining the channels 23. The width of the channels 23 will depend to a large extent on the type of strip material 26 to be used to cover these channels 23. For instance if flat strip material 26 is employed, the channel width may be virtually nothing, whereas if T-section lead strip material is employed, the channel width may typically be 10 mm. The glazing panes 7' are conveniently temporarily retained in position on the flexible sheet 20' by small blobs 22' of plasticine, putty or the like.The portions of the flexible sheet 20' defining the bottoms of the channels 23' should be treated to render them anti-adhesive. The method of construction then proceeds as previously described until the step where the table 16 has just been revolved back through 1800 to its original position and the board supporting the panel assembly is laid on top of the table 16. At this stage, the board, transparent sheet 20' and design 15 are removed to expose the "reverse" side of the panel assembly. The method may then proceed as previously described.

In other modifications of the basic method described, it is possible to dispense with the revolving table 16 and to use, instead, two stiff boards for sandwiching the leaded panel therebetween and manually to turn the sandwiched panel assembly as required. It is also possible, where flat section strip material is used to cover the joints between the glazing panes, to provide virtually no gaps between the confronting peripheral edges of adjacent glazing panes. In this case the glazing panes are cut to butt up against each other. The peripheral edges of the panes are then smeared with sealant material, e.g. silicone, and the glazing panes are butted together so as to interfit in the manner of a jigsaw puzzle. The flat sections of strip material, e.g. of lead, can be either fitted over the joints immediately or after the sealant material has cured to provide substantially liquid-tight joints. It is also possible to construct, section by section, both sides of the leaded panel until the whole panel is complete, by constantly turning the panel over as previously described. This method can accommodate personal time limits, as desired, or time limits controlled by the setting times of the bonding material.

Claims

1. A glazing assembly comprising a first glazing panel (6) laminated to a second glazing panel (40), characterised in that the first glazing panel (6) comprises a number of glazing panes (7) and joint means (25) comprising joining material in the form of a binding and sealing compound or cement for joining confronting peripheral edges of adjacent glazing panes and sealing the glazing panes in a substantially liquid tight manner.

2. A glazing assembly according to claim 1, characterised in that the joint means (25) further comprises strip portions (11, 12) arranged to cover at least one side of each joint between the confronting peripheral edges of the adjacent glazing panes (7).

3. A glazing assembly according to claim 2, characterised in that said strip portions (11, 12) are of a different material, e.g. lead, to that of the joining material.

4. A glazing assembly according to claim 2 or 3, characterised in that the strip portions (11, 12) include an anchoring portion which is anchored in the joining material in gaps (23) provided between spaced apart peripheral edges of adjacent glazing panes (7) to retain the strip portions in position.

5. A glazing assembly according to claim 2 or 3, characterised in that the strip portions (11, 12) are adhered in position over each joint.

6. A glazing assembly according to any one of the preceding claims, characterised in that the joining material comprises silicone sealant material.

7. A glazing assembly according to any one of the preceding claims, characterised in that the confronting peripheral edges of the adjacent glazing panes (7) are spaced apart at least 4 mm.

8. A method of manufacturing a glazing assembly comprising laminating a first glazing panel (6) to a second glazing panel (40), characterised in that the first glazing panel (6) is made by arranging in a plane a number of glazing panes (7) in interfitting relationship so as to define joints between confronting peripheral edges of adjacent glazing panes and joining the confronting peripheral edges of said adjacent glazing panes with joining material in the form of a binding and sealing compound or cement.

9. A method according to claim 8, characterised in that prior to the laminating step at least one side of each joint is covered with strip portions.

10. A method according to claim 8, characterised in that, in the making of said first glazing panel (6), temporary strips (21) of flexible material are prearranged on a flat substantially horizontal support surface (20) along the course of'said gaps, the strips (21) having a width greater than that of the gaps, the glazing panes (7) are then positioned on top of said strips (21) so that the bottom of the gaps formed between the spaced apart glazing panes (7) are closed by the strips (21), the gaps are then filled with said joining material and the temporary strips (21) are subsequently removed.

11. A method according to claim 10, characterised in that the strips (21) are removed after arranging at least one support panel (30) on top of the partially formed first glazing panel and turning the assembly through 1800 so that the glazing panes (7) are supported on the support panel (30) with said strips (21) uppermost to enable their removal.

12. A method according to claim 11, characterised in that the turning of said partially formed first glazing panel (6) is achieved with the aid of a table having a top which is rotatable through at least 1800.

13. A method according to any one of claims 8 to 12, characterised in that the laminating step is performed by arranging the first and second glazing panels (6, 40) in confronting, spaced apart relationship with their peripheries at least partially sealed together, introducing set table liquid resin material between the spaced apart glazing panels and allowing the resin material to set to provide an interlayer bonding the first and second glazing panels together.

14. A method according to claim 13, characterised in that the first and second glazing panels (6, 40) are peripherally sealed with the aid of double-sided adhesive tape material sandwiched between the first and second glazing panels.

15. A method according to claim 14, characterised in that the adhesive tape material is impermeable to the liquid resin material.

16. A glazing assembly constructed and arranged substantially as herein described with reference to, and as illustrated in, Figures 2, 3, 5, 6 and 9, or Figures 2, 3, 5, 6 and 9 as modified by Figure 4 or Figures 7 and 8, or Figure 10 of the accompanying drawings.

17. A method of manufacturing a glazing assembly substantially as herein described with reference to, and as illustrated in, Figures 2, 3, 5, 6 and 9, or Figures 2, 3, 5, 6 and 9 as modified by Figure 4 or Figures 7 and 8, or Figure 10 of the accompanying drawings.