Abstract:
A foil applicator for evenly applying an adhesive backed foil to edges or pieces of stained glass. The applicator includes guide members which direct a foil strip from a foil spool through an adjustable grasping roller mechanism and past a horizontal, raised planar table where foil is applied manually to the edges of glass pieces, nuggets, or jewels.

Description:
FIELD OF THE INVENTION  
         [0001]    This invention relates to a tape dispenser and particularly an apparatus and method for dispensing and applying metal foil to an edge and/or periphery of stained glass.  
         BACKGROUND OF THE INVENTION  
         [0002]    Stained glass articles are formed of numerous small pieces of variously colored glass or plastic which are joined together along adjacent, butting edges to form the desired finished article. Typically, each stained glass piece is edged with a thin strip of metallic foil, such as copper foil, to form a base for the application of lead solder to join adjacent, butted pieces together.  
           [0003]    The present invention relates to an apparatus for applying foil to the edges of stained glass. Conventional methods of foiling stained glass present numerous difficulties. The narrow width of the foil and the thinness of the stained glass make it difficult to precisely align the foil on the edge of a piece of stained glass such that equal amounts of the foil overlap or are folded over both opposed surfaces adjacent to an edge of the stained glass. The conventional method of applying foil also results in numerous cuts from glass. In addition, many foilers on the market today require orientation of the glass piece in a vertical manner, which is unwieldy. Furthermore, it is difficult to obtain an even distribution of foil along the edge of the glass, and foil often tears in the application process.  
           [0004]    In order to accomplish the desired application of the foil to the edge and/or peripheral surface of the glass, foil dispensers or applicators are used. During the foiling process, the designer manually applies the adhesive side of the foil to the edge and/or periphery of the glass as the copper foil rolls off a spool or turntable and the paper backing on the foil is stripped therefrom.  
           [0005]    In response to these problems with the conventional method, a variety of tools or applicators have been developed. Such tools are manually operated devices which typically guide the adhesive surface of the foil as it is unwound from the spool in a channel or other alignment device through which the edge of a piece of stained glass is passed. The channel is designed to evenly align the foil with the piece of stained glass and to provide equal amounts of overlap of the edges of the foil with the piece of stained glass. Examples of such prior art tools are described in U.S. Pat. Nos. 4,115,180; 4,274,904; 4,555,297; and 5,356,505.  
           [0006]    However, all such previously devised foil applicators require the user to manually or mechanically urge the piece of stained glass over the foil on one horizontal or vertical plane. Prior art apparatuses do not accommodate large, bulky pieces of glass, jewels, or nuggets, and do not leave enough room for a user&#39;s hands to manually crimp, if necessary, a large or bulky piece of glass. Prior apparatuses also have a problem of the foil pulling back toward the roll, or adhering or moving to other parts of the foiler in an undesirable manner. Furthermore, some conventional foil applicators require a power supply, or are encumbered with a complex system of spools and guides.  
           [0007]    Thus, it would be desirable to provide a stained glass foil applicator that employed two levels, with an upper table high enough to leave a large unobstructed area for various shapes and sizes of glass, and allow vertical space between levels for manual hand crimping of thicker glass. It would also be desirable to have a mechanism for grasping the foil, and keeping it adhesive side out, such that the foil remains in place, and prevents it from retracting back into the spool or adhering or moving to an undesirable location on the foiler. Finally, it would also be desirable to provide a simple, sturdy, and highly portable foil applicator that did not require an electricity source.  
         SUMMARY OF THE INVENTION  
         [0008]    The present invention describes a foil applicator for applying foil to the edges of glass pieces or the like, comprising a horizontal base having a first surface defining a work area and an attachment area. The work area includes a foil support, a foil splitter, and a rotatable roller. The invention further includes a horizontal table for receiving the glass pieces. The table is fixedly attached to the attachment area of the base, such that the table is at a different plane than the first surface of the base.  
           [0009]    The present invention is also directed to a foil applicator for applying foil to the edges of glass pieces or the like, comprising a horizontal base having a first surface defining a work area and an attachment area. The work area includes a foil support comprising a plurality of guide members positioned to support the foil onto the first surface of the base. a foil splitter, a rotatable roller removably positioned on the work area, and means to adjust the position of the roller with respect to first surface of the base. The foil applicator also includes a horizontal table for receiving the glass pieces. The table is fixedly attached to the attachment area of the base, such that the table is at a different plane than the first surface of the base.  
           [0010]    The present invention solves at least some of the problems noted above, by providing a raised work table above the base of the applicator. The present invention also includes a roller mechanism that can be vertically adjusted, and is removable. The present invention includes various sizes of rollers that can be placed on the foiler, depending on the size of the copper foil that is being applied.  
           [0011]    The stained glass foil applicator includes a base, and a raised upper table, which accommodates large and bulky pieces of glass, nuggets, and jewels. The applicator also includes a means mounted on the base for receiving a spool of metallic foil having an adhesive surface covered by a removable backing. Guide means are mounted on the base and spaced from the spool receiving means for guiding the foil from the spool to a splitter peg where the foil is separated from the backing, through an adjustable roller, and then guided across a table where the foil is adhesively applied to an edge of a piece of stained glass urged by a user past the application point. After primary application to a piece of glass, the foil tail end remains in place in the roller mechanism, adhesive side out, making it readily accessible for the next application.  
           [0012]    There are several advantages to the above modifications in the foil applicator described herein. Unlike conventional foil applicators, the raised table allows for easy manipulation of glass, nuggets, or jewels and even deposition of foil along the edges of these materials. It provides a large, unobstructed area for foiling large, unusually shaped pieces. In addition it allows the operator to grasp the underside of the piece for better manipulation of the piece. Further, the foil apparatus of the present invention easily applies foil of different widths to glass pieces and pieces of all sizes and shapes.  
           [0013]    Additionally, the roller in combination with a guide mechanism, which acts as a foil control guide, firmly grasps the foil while the foil tape is being applied to the glass edge, preventing self-adhesion or retraction back into the spool.  
           [0014]    Preferably, in use the control and increased support provided by the table is particularly beneficial to those with poor hand/eye coordination. The table is also readily available for close work, and foiling large bulky objects because it accommodates objects of all sizes, such as jewels and nuggets.  
           [0015]    Another advantage to the user is the portability of the unit. Unlike conventional foil applicators, the upper level surface foil applicator can be easily placed in a user&#39;s lap while sitting, or used on a countertop or work bench. Additionally, the unit does not have cumbersome electric supply attachments or numerous parts that make it awkward to move.  
           [0016]    Further advantages, features, and objects of the invention will be apparent from the following detailed description of the invention in conjunction with the associated drawings. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0017]    [0017]FIG. 1 is a perspective view of the of the foil applicator of the present invention.  
         [0018]    [0018]FIG. 1A is a blown up perspective view of the foil splitter, illustrated in FIG. 1.  
         [0019]    [0019]FIG. 1B is a side plan view of the roller of the present invention.  
         [0020]    [0020]FIG. 2 is a top plan view of the foil applicator of FIG. 1..  
         [0021]    [0021]FIG. 3 is a side view of the foil applicator of FIG. 1.  
         [0022]    [0022]FIG. 4 is an end view of the foil applicator of FIG. 1.  
         [0023]    [0023]FIGS. 5, 6, and  7  are top plan views of the foil applicator with application process illustrated. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0024]    Reference is now made to FIG. 1 for an illustration of the foil applicator  10  of the present invention. Foil applicator  10  comprises a horizontal base  12  having first, upper surface  14 , sides  16  and a lower surface  18 . Optionally, the lower surface  18  of base  12  can include non-skid buttons or feet  20  to support the base  10  and restrict movement on a flat surface such as a table.  
         [0025]    Located at one end of the base  12  is a table  22  of generally the same width and depth as base  12 . The table  22  is preferably fixedly mounted on the base  12  and occupies approximately one-third to one-half of the surface area of the base  12  as illustrated. The table  22  has an upper surface  24  and preferably a diagonally-shaped edge  26 . Both the base  12  and the table  22  are preferably made of a rigid material, such as wood, high pressure laminate, plastic, metal, particle board or hard rubber.  
         [0026]    The upper surface  14  of base  12  is identified by a series of guide members  30 ,  32 ,  34  and  36 . Guide members  30 ,  32 , and  34  are designed in triangular arrangement on the surface  14 , as illustrated in FIG. 2. The purpose of these guide members is to seat and stabilize a foil roll  70 , as illustrated in FIGS.  5 - 7 . It is within the scope of the present invention to have more or less than  3  guide members as desired. As illustrated, each of the guide members  30 - 36  preferably include a post  38  and a cap  40 . Although the cap  40  is preferred, it is not necessary. The fourth guide member  36  is designed to assist the guidance of the foil tape  72  as it leaves the foil roll  70 , illustrated in FIGS.  5 - 7 .  
         [0027]    In addition to the guide members  30 - 36 , the upper surface  14  is characterized by a foil splitter  42 , illustrated in FIGS. 1 and 1A. The foil splitter  42  includes a main post  44 , a generally cylindrical post. The top surface  46  of the main post  44  extends above the upper surface  24  of table  22 . Main post  44  is further characterized by a cutaway section, which forms a lower surface  48  and a vertical wall  50 . The height of the lower surface  48  above the upper surface  14  is similar, if not virtually the same as the height of surface  24  above the upper surface  14 . The lower surface is further characterized by guide member  52 , similar in size and shape to guide members  30 - 36 . The guide member  52  is positioned on the lower surface  48  such that a slight gap (not shown) is formed between the guide member  52  and the vertical wall  50 . The gap is designed to receive and split the foil tape  72 , which will be described with reference to FIGS.  5 - 7 .  
         [0028]    Upper surface  14  is further characterized by a removable circular and rotatable roller  54 . The roller  54  is preferably made of plastic, wood, metal or hard rubber. As illustrated in FIG. 1B, the roller  54  includes an upper lip  56  characterized further by a recessed cylindrical surface  57 , and a lower lip  58  characterized by a recessed cylindrical surface  59 . The surfaces  57  and  59  define a channel  60 . The width of the channel  60  depends on the width of the foil tape  72 . Situated between channel  60  is interior channel  61 . The interior channel contains a circular rubber piece  63 , similar to a conventional O-ring. The rubber piece  63  aids in applying the foil portion  74  to the glass piece as will be described later. As illustrated in FIGS. 1 and 2, indicia of size (e.g., “{fraction (3/16)}” inch) is typically imprinted on the outer surface of the roller  54 . The roller  54  further includes a passageway  62 , illustrated in phantom, designed to receive an upright threaded bolt  64 , which extends through the base  12 , and is held by means of a nut or fastener (not shown). The roller  54  is rotatably mounted to the base  12  by the bolt  64 , a co-acting lower threaded nut  66 , such as a wing nut, and an upper threaded nut  68 , also such as a wing nut. In this manner, the height of the roller  54  above the surface  14  of base  12  is adjustable. Preferably, the height of the roller should be adjusted such that the surface  59  is slightly lower than surface  24 . The roller  54  can be removed from the apparatus  10  by loosening the nut  68 . It is understood that the roller  54  may be changed to adjust to varying widths of foil tape  72 .  
         [0029]    Located adjacent the roller  54  is yet another guide member  55 , which acts as a foil control guide to operate in concert with the roller  54  to guide and restrain the foil  74 . This will be explained with further reference to FIGS.  5 - 7 .  
         [0030]    As illustrated in FIGS.  5 - 7 , the tape  72  of the foil roll  70  typically has a foil portion  74  made of copper or other suitable foil material with a self-adhering material such as adhesive on one face of the foil portion  74 , and a backing  76  normally of protective paper or another suitable material. As illustrated in FIGS.  5 - 7 , the foil tape  72  passes through the foil splitter  42 , which separates the foil portion  74  from the backing  76 . In the preferred embodiment, the foil portion  74  passes through the foil splitter  42  and between the roller mechanism  54  and the foil control guide member  55 . The foil  74  then continues around the roller mechanism  54 , where the foil portion  74  is ready for application with the adhesive side facing outward.  
         [0031]    Operation of the Apparatus:  
         [0032]    The operation of the apparatus  10  is now described with reference to FIGS.  5 - 7  Prior to the application of the foil  74  to the edge of a glass piece, the height of the roller  54  is adjusted to the appropriate vertical height of the surface  24  using the nuts  66 , 68  such that the foil  74  exits the roller  54  at the same or similar height as the surface  24 . The width of the foil  74  is then matched with the appropriately sized roller  54 . For example, a {fraction (3/16)}th inch foil  74  should be matched with a roller  54  having a {fraction (3/16)}th inch channel  60 . Likewise, a ¼th inch foil  74  should be matched with a roller  54  having a ¼th inch channel.  
         [0033]    The foil roll  70  is positioned on the 3 guide members  30 ,  32 ,  34  such that the foil tape  72  will unroll toward guide member  36 . If desired, a restraint mechanism (not shown), such as a rubber or elastic band, can be pressure fitted over the foil roll  70  and secured by other guide members (not shown) to keep the foil roll  70  from unwinding during installation, operation and transport.  
         [0034]    The end of the foil tape  72  is then fed around guide member  36  to foil splitter  42 . At this juncture, the foil portion  74  is separated from the backing  76 , and the foil portion  74  is fed to the roller  54  such that the foil portion passes between the roller  54  and the foil control guide member  55 . The foil portion should be snug fit within the channel  60  of the roller  54 . This configuration provides an additional advantage because the slight adhesion of the adhesive side of the foil  74  with the foil control guide member  55  provides stability and keeps the foil  74  in place at all times.  
         [0035]    Scissors or other cutting implements are then used to snip the end of the foil portion  74  in order to insure that the end of the foil portion is now tucked into the channel  60  as illustrated in FIG. 5. A glass piece  80  is then placed flat on the surface  24  of the table  22  and urged against the adhesive backing of the foil portion  74  resting within the channel  61  of the roller  54 . It is preferred to begin at a corner of the glass piece  80  if the piece has a corner.  
         [0036]    With firm pressure, the glass piece  80  is urged against the foil portion  74  as the piece  80  is rotated, illustrated in FIG. 6. The glass piece  80  should be kept in continuous contact with the foil  74 , which should also be kept in continuous contact with the rubber piece  63  in channel  60  of the roller  54 . The relationship between channels  60 ,  61  assist the foil in crimping around a glass piece. The rubber piece  63  acts as a bumper to facilitate the movement of the glass piece  80  on the roller  54 .  
         [0037]    Once the glass piece  80  has made a full rotation, illustrated in FIG. 7, the foil portion can be cut with a scissors. At this point, the foil portion  74  remains lodged in the channel  60  of the roller  54  ready for the next piece.  
         [0038]    Because the glass piece  80  is resting on the surface  24 , it is situated at a height above the foil roll  70  and the various guide members. Therefore and unlike other foiler apparatuses of the prior art, larger, more concave pieces of glass can be easily foiled without disruption by the guide members situated on surface  14 . Thus, a glass piece could actually be large enough to hover directly over the foil roll  70  as it is being foiled without disruption.  
         [0039]    It is understood that the various preferred embodiments are shown and described above to illustrate different possible features of the invention and the varying ways in which these features may be combined. Apart from combining the different features of the above embodiments in varying ways, other modifications are also considered to be within the scope of the invention. While the improved foil applicator and method for using same have been described in connection with the preferred embodiment, it is not intended to limit the invention to the particular forms set forth, but on the contrary it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims. It is understood that in the claims, means plus function clauses are intended to encompass the structures described above as performing their recited function, and also both structural equivalents and equivalent structures. As an example, though a nail and a screw may not be structural equivalents insofar as a nail employs a cylindrical surface to secure parts together whereas a screw employs a helical surface, in the context of fastening parts, a nail and a screw are equivalent structures. Additionally, the present invention describes the means for rotatably attaching the roller to the first base as a bolt with wing nuts. It is also within the scope of the present invention to use other attachment devices such as a regular nut and threaded post or a slide post and friction clips.