GB2436847A - Stained Glass Window Frame Manufacturing Method - Google Patents

Abstract

An <B>Outside Back Plate</B> 1 precisely cut out to a design, is attached to a precisely cut out <B>Middle Spacer Plate</B> 2 of similar design but with enlarged apertures (resulting in narrower profiles left in the panel) in which are located glass segments. An <B>Inner Front Plate</B> 3 of precisely cut design IDENTICAL to the Outside Back Plate may be aligned with, then secured to the Middle Spacer Plate to contain the glass segments.

Description

1.

2436847

STAINED GLASS WINDOW FRAME MANUFACTURING METHOD

BACKGROUND

DEFINITION OF STAINED GLASS.

The term 'Stained Glass' is no longer narrowly applied, as it was originally in the past, just to window glass that has been stained with a silver oxide and then heated to a high enough temperature to cause a molecular reaction with the glass substrate, causing a permanent staining of the glass, usually yellow or orange in colour, where the oxide had been brushed on.

Essentially, 'Stained Glass' and 'Stained Glass Windows' are recognised today widely and almost universally, in common parlance, in whatever language, as pertaining to a visual effect obtained in glazing schemes, and structures, where individual glass segments of varying shape and size, whether coloured or clear glass, are individually contained by frames of lead amalgams (sometimes copper and other amalgams), of regular or varied profiles and widths, which are then soldered together to form a composite panel of 'leaded up' glass pieces, thereby presenting a recognisable 'stained glass' effect, more formal or stylised in design appearance than plain regular panes of glass in glazing schemes, where no individually 'leaded-up' segments of glass are involved.

SOME EXAMPLES (but not limited to these) which are widely termed and understood to be 'Stained Glass', and therefore to be included in the meaning of 'Stained Glass' are:

1. Stained Glass Windows; 2. Tiffany-style lampshades; 3. Suncatchers, which incorporate separate pieces of glass; 4. Lead framed glass:- window roundels and panels, diamond shaped quarries, and rectangular 'leaded lights';

2. Articles commonly described as 'stained glass' or 'leaded lights', in advertisements in Yellow Pages, and listed as such in Glass, Glazing, and Giftware Trade Fair indexes.

2.

PROBLEMS WHICH THIS INVENTION SEEKS TO OVERCOME

1. The current stated intention of some governments, in countries such as the USA and within the EC, is to ban the use of lead in new building constructions. In such countries Stained glass window manufacture and installation in buildings, using current methods of manufacture involving the use of lead, may become illegal. Yet the trend is towards a greater use of stained glass of all kinds, and ever-larger sizes, in building manufacture.

Hitherto, also, most if not all stained glass window constructions have required the use of lead to frame individual glass segments and create composite panels by soldering the lead sections together. This traditional manufacturing process is time consuming, expensive, and is skilled work by artisans generally outside the building trade, and therefore less controllable in scheduling terms; additionally, this method of manufacture leads to potential weakness in the strength of the windows, as strong winds may blow windows in, particularly when lead corrosion takes place over time. Typically cathedral windows require expensive re-leading every 100 to 150 years.

2. The glazing of larger stained glass windows has necessarily required the use of strengthening bars of some kind to be incorporated in the artistic design, to prevent windows from subsequently being blown in by high winds or, on occasions, blown out by fire explosion from within the building; as also, to support and distribute the heavy weight of the leaded panels onto the supporting masonry of the window aperture. Such strong thick steel bars within the glazing scheme have had the effect of strongly influencing the artistic design, and restricting and limiting freedom of design expression.

3. Individual stained glass leaded panels are by nature relatively fragile - yet require to be hoisted in place externally by pulley, rope or crane, and installed from scaffolding erected sometimes high up the outside of a building.

4. There are considerable Health and Safety concerns about men working and lifting objects that could fall from high up the outside of a building.

5. Erecting scaffolding is time consuming, expensive, and it is usually only practical to carry out window installation during new building construction.

6. In cases of EXISTING, previously constructed, tall buildings and skyscrapers, it is impractical to install new stained glass windows structures high up involving external scaffolding, so at present this is not a realistic option for builders.

7. In some more exposed glazing schemes, vibration problems may occur from heavy traffic or aircraft noise; and in some zones, earthquake vibration damage needs to be guarded against, as 'Stained Glass' windows are by nature unstable in such circumstances.

3.

STATEMENT OF INVENTION

A precise potentially-modular industrial method of manufacturing window glazing frames in a two, three or more-part composite panel assembly, using exact computer-guided cutting processes, permitting the manufacture of Stained Glass-type Windows of both small and potentially very large size, suitable for installation:

(a) without the requirement to use lead to frame individual glass segments and panels.

(b) without the requirement of incorporating strengthening support bars in the artistic design arrangement,

(c) without the requirement to construct external scaffolding for installation of the window high up a building, as this manufacturing method allows that the whole modular construction can be installed from within a building;

WHICH composite section frame is made up of at least two plates, normally three plates, which may be of the same or different material thicknesses;

- which composite frame assembly is usually flat (but not necessarily, as in the case of three-dimensional glazing structures);

- which composite frame is normally, but not necessarily 'H' shape in side profile (being welded, screwed, plugged or glued together in some way);

ESSENTIALLY, all of these plates being precisely cut out to a design, by computer-guided abrasive Water-jet, Laser or other such precise cutting process, from flat sheets of stainless steel, aluminium or other material;

ESSENTIALLY, all of the two, three (or more) plate(s) having the same cut out design, so that when they are superimposed exactly together, the one cut out aperture design pattern is seen through all of the composite assembled sheets;

Of which plates, the first TWO shall be termed (facing the inside of the window to be installed) the Outer Back Plate and Middle Spacer Plate:

- which Middle Spacer Plate is designed to be positioned precisely and centred on this Outer Back Plate, and then spot welded or attached securely to it;

- which Middle Spacer Plate, being of similar out-out design as the Outer Back Plate but precision cut to a wider aperture size and therefore narrower width of remaining material, enables individual glass (or similar looking material) segments (whether hand cut or, more precisely, cut by computer guided Water-jet or similar cutting process) to be located and securely held

4.

(with clear water-proof silicon caulking, sealant, or similar - which material has the potential additional advantage of being able to absorb vibration and shock from noise or earthquake) in the spaces formed between the Middle Spacer Plate cut out sections (these glass segments therefore also being backed bv the Outer Back Plate, and (in cases of three-part or more composite assemblies) fronted bv the Inner Front Plate):

with a further THIRD plate (in cases of three-part composite layers),

which shall be termed the Inner Front Plate: which Inner Front Plate (following the insertion of the glass segments in the Middle Spacer Plate apertures) is then welded (or screwed, plugged, studded or attached securely) onto the inside-facing surface of the Middle Spacer Plate:

WHICH composite assemblies, of Outer, Middle and Inner Plates, potentially may be assembled as modular constructions, in cases of very large window spaces, from several composite sub-assemblies, with joins between these sub-assemblies welded, screwed or glued together securely, to make one potentially very large composite assembly;

- which joins, between the several sub-assemblies, optionally, may have a thin, vibration-absorbing, single-sided adhesive tape, of a material with characteristics like polyurethane, added to one butting-up surface of the join before the two faces are brought together and secured;

- which butting-up surfaces, optionally, may have projecting studs from one face of such joining Outer Plate surfaces, to aid exact location of the two Outer Plates (with their attached Middle Plates);

- which Inner Plate, in cases of larger window modular-constructions, may also be composed of several sub-assemblies of Inner Plates in order to make up the one larger Inner Plate;

- and which sub-assemblies of Inner Plates, optionally, may be deliberately cut to different joining positions than the joining positions of the underlying Outer/Middle composite plates, so that when each sub-assembly Inner Plate is subsequently screwed or welded onto the adjoining Outer/Middle composite plate assembly, the joins of the Inner Plate will be offset to the joins of the Outer/Middle Composite Plates, giving greater overall strength to the window and allowing for design of windows of greater size.

5.

ADVANTAGES OF THIS INVENTION

In general, this precisely cut, composite, and potentially modular, method of manufacture offers many advantages in the construction, and installation of Stained Glass Window-type glazing structures.

It provides for:

1. Compliance with new Health and Safety legislation in not using lead during the manufacture or at any time.

2. Greater safety in installation. No requirement for exterior installation using scaffolding high up a building, with operatives exposed to danger from such situations.

3. Interior installation gives no hold ups in schedule from weather changes,

4. Glazing structures can now be manufactured, installed and scheduled in line with normal architectural building practices,

5. Glazing structures can be constructed very much larger in size, and may be vertical or horizontal, flat or three-dimensional.

6. Glazing structures may now be installed from inside high up EXISTING tall buildings (such as skyscrapers) readily and inexpensively, without the need for external scaffolding or operators working outside the building, using goods lifts/elevators or stairways to transport frames and glass.

7. Lighter weight of glazed structures may be achieved from not using traditional lead frames around glass segments; as also from, using stainless steel for the frame manufacture, where, after cutting out the shaped holes for glass insertion in the sheet metal, the resultant frame is surprisingly light in weight for its size, yet very strong and long lasting; aluminium frames may be lighter still, but may not have quite the same strength and long lasting, low maintenance, qualities as stainless steel.

8. If glass segments are precision-cut by computer-guided Water-jet, or similar process (and then labelled), direct installation of the glass segments in situ can be the norm, carried out supervised non-skilled operatives, which installation can be planned for, and be scheduled.

9. Stronger constructions, with less weakness of panels and joints.

10. Distribution of weight is supported evenly throughout structure,

11. Panel structures can be assembled in modules, being securely welded, screwed or attached directly onto an angle-iron frame, fixed in the window opening, as each panel frame is added and welded together.

12. The angle-iron fixing frames attached to the masonry walls in the window openings also can be installed from inside the building (in larger window openings this can be done in smaller sections fixed to the masonry walls and then welded together to make up one continuous angle-iron frame).

13. Very long lasting window constructions and glazing structures, particularly if high grade stainless steel is used in the construction.

14. Potentially large and significant cost savings,

15. Less maintenance or need for subsequent inspection,

6.

16. Ease of on-site replacement of broken glass segments may be achieved by removal of local Inner/Front Plate section, and replacing with new sealed-in glass piece; alternatively cracked glass may be sealed in place.

17. Greater resistance against vibration from traffic and aircraft noise,

18. Greater protection from potential earthquake risk problems,

19. Greater freedom in artistic Design conception, without the need for supporting bars or concrete/masonry divisions in the window openings;

20. Frame Panel metal can be sprayed or hand painted decoratively in gold, or any colour, after priming steel with a ferrous metal primer.

21. Potential artistic design opportunities are presented by using multi-composite panel structures to create several layers of coloured and painted glass on top of one another to create interesting effects.

22. Architects have the option to design and get frames manufactured themselves, according to their customer's wishes, and in doing so by-pass much of the normal required time scheduling, and some of the costs, of traditional stained glass manufacturing; at the same time, architects also have the opportunity, if they so wish, to select the clear/coloured glass and get it cut exactly to size by computer-guided Water Jet; which cut glass can then be: either labelled and delivered direct to site for installation (if not to be worked on), or, delivered to a Stained Glass Studio, being only that glass that is required to be worked on ( being already cut exactly to size, this saves time, money, and speeds up the work schedules required).

INTRODUCTION TO DRAWINGS

Examples of the invention will now be described by referring to the accompanying drawings:

Figure 1. - shows typical flat plates l.,2.,3. cut out by a computer-guided cutting process, such as Water Jet, to a common design (which is here is shown as an example for illustration purposes only, and does not constitute any part of the claimed invention), together with typical angle-iron construction 4. to attach the two, or three part, composite plate assembly to the masonry walls of the window opening.

Figure 2. - shows detail of a typical two-part basic composite plate assembly, with the Outer Back Plate 2.1 attached by a spot weld 2.3 to the common design (but narrower profiled) Middle Spacer Plate 2.2.

Figure 3. - shows details of typical three-part composite plate assembly, with the basic composite assembly of 3.1 and 3.2, as described in Figure 2., added to with a third Inner Front Plate 3.3 attached (by plug welding or screw 3.5).

7.

Figures 4,5,6 - show details respectively, as seen from a Side perspective, of the typical basic two-part plate assembly, three-part assembly, and typical five-part assembly, with in each case the Outer Back Plates, 4.1, 5.1,6.1, spot welded on to the Middle Spacer Plates, 4.2, 5.2, 6.2. Figures 5. and 6. also show the additional Inner Front Plates 5.3 and 6.3 attached typically by plug welds 5.5, 6.5, or by removable screws 5.4. Figure 6 additionally shows a fourth Inner Front Plate 6.4, IDENTICAL to the Inner Front Plate 6.3, which is attached by welds 6.6, or plug welds 6.9, or by removable screws 6.8, to a further Middle Spacer Plate 6.7 IDENTICAL to the first Middle plate 6.2, which constitutes a typical five-part assembly.

Figures 7,8,9 - show details, as seen from a Plan perspective, of typical two-part basic composite plate assemblies of different shaped designs; being Random-shaped 7., Rectangular-shaped 8., and Round-shaped 9.. The narrower-profiled Middle Spacer Plates 7.2, 8.2 and 9.2 can be seen clearly superimposed and centred on the Outer Back Plates, 7.1,8.1 and 9.1.

Figures 10,11,12 - show the same Plan details as figures 7,8,9 but with the addition of typical inserted glass segments, shown here typified by dotted lines, 10.1,11.1,12.1 (for illustration only, and not anything to do with the invention here claimed), inserted in apertures cut out between the narrower-profiled Middle Spacer Plates.

Figures 13,14,15 - show the same Plan details as figures 10,11,12, but with the overlay of Inner Front Plates 13.1,14.1, to exemplify the visual effect from inside the building of adding these Inner Front Plates to the Random, Rectangular and Round shaped design frames of Figures 7,8,9, respectively. (Likewise, Figure 15 could show the visual effect of the fifth, Inner Front Plate, if it were a five-part composite assembly, as in Figure 6.). The typified glass 13.2,14.2,15.2, for illustration purposes only, can be seen projecting out from the sides of the Inner Front Plates in each case.

Figures 18,19,20 - show typical two-part, 18, three-part, 19, and five-part, 20, composite plate assemblies seen from the Side View, as Figures 4,5,6, but with the additional of typical glass components (here shown for illustration purposes only, and not part of the claimed invention here described) inserted in the apertures between the profiles of the Middle Spacer Plates, respectively 18.2,19.3 and 20.3, as also with the typified glass sealant (also shown for illustration purposes only and not part of the claimed invention) 18.7, 19.5.

Figure 21 - shows a typical three-part assembly, of Outer Back Plate 21.1, Middle Spacer Plate 21.2, and Inner Front Plate 21.3 - in this illustration illustrated by screw fixing 21.4 to the Spacer Plate 21.2., for ease of removal later, should this be required for replacing any broken glass, for instance. Additional glass segments 21.8 and sealant around the glass (both shown for illustration purposes only and not part of the claimed invention), are also shown, together with the OPTIONAL protective cover 21.6 (not claimed as part of the invention here described, and shown for illustration purposes only) attached here typically, but not necessarily, by pre-tapped threaded spacer 21.5, which has been spot-welded onto the outward-facing back-face of the Outer Back Plate 21.1, into which a cap screw 21.7 has been inserted.

8.

Figure 22 - shows the assembly in Figure 21 with Plan view, along section line 22.1, as seen from the outside of the window, and with the optional outer protective cover in place (shown for illustrative purposes only and not part of the invention here claimed).

Figures 30,31 - show an example of a typical method of offsetting plates by horizontal 31., and vertical 30. placement, giving great strength from the horizontal plate attachment on both sides to the masonry walls. In this case the standard panel sheet size is 2 metres x 4 metres, giving a window size of 16 metres in height x 4 metres in width. As a single panel sheet can be cut out to a size larger than this, 6 metres x 2 metres, the arrangement shown with this size of plate could produce a still very strong, larger window, of dimensions 24 metres in height x 6 metres in width. IMPORTANTLY, although the panels here are shown in regular rectangular shape form, giving obvious join lines, the actual join/cut lines may be anywhere within each panel area. An irregular join line therefore is quite possible, the cutting process bisecting the centre of the Back Plate/Spacer Plate along that line.

Figures 32,33 - show how staggered offsetting of the larger size plates (6m x 2m) within the vertical arrangement Figure 30. may be further used to produce much larger window glazing schemes; in this example 12 metres wide x almost any height - several hundred metres in height, if need be - yet still with great strength against wind, and pressure, from both outside and inside the building, as with explosion for instance..

Figures 34, 35 - show as an example, based on Figures 30, 31, (andfor illustrative purposes only, not part of the invention here claimed) how a typical larger stained glass window could be constructed in modular fashion using 4m x 2m panels; offset vertically (Fig. 34.) and horizontally (Fig.35.) - or vice versa. Potentially, as the Outer Back Plate may be cut out from thicker sheet material, there may be greater strength if the horizontal panels attached to the masonry side walls were to be applied to this Outer Plate/Spacer Plate assembly, with the vertical panels being the Inner Plate. This would be particularly relevant in very large window constructions, such as in Figures 32,33.

HERE FOLLOW THE DRAWINGS IN 6 PAGES

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Claims (12)

1. An industrial method of manufacturing Stained Glass window glazing frames m exactly aligned composite plate construction form, using precise computer guided cutting processes.

2. A method according to claim 1. without the use of lead m the manufacture.

3. A method according to claim 1. using lead in the manufacture to frame glass.

4. A method according to claim 1. using stainless steel in the manufacture.

5. A method according to claim 1. using aluminium m the manufacture.

6. A method according to claim 1. using any other material m the manufacture.

7. A method according to claim 1. usmg glue materials in the manufacture.

8. A method according to claim 1. using caulking or sealants in the manufacture.

9. A method according to claim 1. using locating studs in the manufacture.

10. A method according to claim 1. using vibration absorbing materials.

11. A method according to claim 1. with partially or wholly welded construction.

12. A method according to claim 1. with plates partially or wholly screw fixed.

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