Abstract:
Artistic panes having flat and planar margins with laterally offset central regions and deformations, as well as devices and methods for making the same, are shown and described. Devices and assemblies for manufacturing such artistic panes incorporate support members and raised boundary members, and can incorporate masses and/or piles of powder to create various deformations in the artistic panes. Methods of manufacturing such artistic panes can incorporate slump processes, sag processes and rolling processes.

Description:
This is a divisional application of Ser. No. 10/142,665 filed May 8, 2002, now abandoned. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention is directed toward devices, systems and methods for use in manufacturing window panes, windows, door lites, and similar products. 
   2. Description of the Related Art 
   Windows incorporating panes of glass or other materials have been commercially available for hundreds of years. During that time period, many developments have taken place in the art of fixed windows, movable windows, French doors and lites for doors and for installing next to doors. For example, windows have been developed that filter out ultraviolet light, that resist scratching or shattering, that do not form jagged edges when broken, or that have other features making the glass suitable for special applications. 
   For most applications, advancement in glass technology has been directed toward improving visibility through the glass or for improving other features of the glass without adversely effecting visibility. 
   Artistic windows, such as decorated windows or stained glass windows, are designed to be attractive. Visibility through an artistic window is not necessarily the primary goal. Consequently, artistic windows have been developed with beveled edges, etched surfaces, multiple colors or embedded objects. 
   In the case of float or sheet glass, whether it is clear, etched, frosted or otherwise treated, the perimeter of the sheet is flat and planar and can easily be inserted into a frame. For odd shaped glass, however, where the boundary is not planar, a standard frame will not work. In such cases, the glass is typically separated into small pieces which are interconnected by cames to form decorative windows. The decorative window can then be framed within a traditional window, or can be inserted into a door for use as a door lite, or inserted into a wall for use as a side lite or a re-lite. 
   Accordingly, there is a need in the industry for an improved system that can incorporate odd shaped panes into traditional windows, doors and walls. 
   BRIEF SUMMARY OF THE INVENTION 
   The present invention is directed toward devices, systems and methods for manufacturing artistic panes, doorlites and windows incorporating artistic panes, and the like. Embodiments of the present invention allow an operator to deform a pane into a complex shape, while retaining a flat and planar margin. As a result, the artistic pane can be inserted into a traditional window or lite. 
   One embodiment of the present invention incorporates an artistic pane having a unitary body with a central region and a marginal region. The central region has a first portion that is generally planar, and a plurality of second portions that are laterally offset from the first portion. The offset first and second portions give the artistic pane a complex surface texture. The marginal region is offset laterally with respect to the first portion of the central region. In addition, the marginal region is substantially flat and planar to facilitate insertion of the artistic pane into a frame or came of a window or lite. 
   Another embodiment of the present invention is directed toward a device for making such windows. The device incorporates a support member having an upper surface, and at least one raised boundary member positioned on the upper surface of the support member. The upper surface of the support member is made from a refractory material, and the entire support member is configured to fit within an oven during use. The raised boundary member is disposed around an enclosed portion of the upper surface of the support member. An inner edge portion of the raised boundary member is flat and planar and has an upper surface made from a refractory material. The inner edge portion of the raised boundary member is adjacent to the enclosed portion of the support member. As a result, when a sheet of glass is placed over both the inner edge portion of the raised boundary member and the enclosed portion of the support member, and is heated above a thermoplastic temperature, the glass will sag against the enclosed portion of the support member, but will remain flat and planar along the inner edge portion of the raised boundary member. Thus, the processed sheet of glass will have a central region that has an artistic shape, and a marginal region that is offset laterally from the central region and that is flat and planar to facilitate insertion of the pane into a window, door or wall. Embodiments of this invention can incorporate various bodies positioned within the enclosed portion of the support member to deform the shape of the sagging glass and create additional artistic contours in the central portion of the glass. 
   Another embodiment of the present invention is directed toward a method for forming artistic panes of glass. The method includes the steps of heating a sheet of material to a temperature in excess of the thermoplastic point of the material, deforming a central portion of the sheet and material into a complex shape, and retaining a marginal portion of the sheet of material in a planar shape. The deforming step of the method can be performed by sag or slump processes, or by rolling processes. 

   
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       FIG. 1  is an isometric view of an artistic pane according to an embodiment of the present invention. 
       FIG. 2  is a plan view of the artistic pane of  FIG. 1 . 
       FIG. 3  is a side view of the artistic pane of  FIG. 1 . 
       FIG. 4  is a sectional side view of the artistic pane of  FIG. 1 , viewed along Section  4 — 4  of  FIG. 2 . 
       FIG. 5  is an isometric view of a device for forming an artistic pane according to an embodiment of the present invention. 
       FIG. 6  is an exploded view of a sheet of glass and an assembly for forming an artistic pane according to another embodiment of the present invention. 
       FIG. 7  is a cross-sectional view of a sheet of glass and a device for forming an artistic pane according to an embodiment of the present invention, shown prior to deforming the glass. 
       FIG. 8  is a cross-sectional view of the glass and assembly of  FIG. 7 , shown after deforming the glass. 
       FIG. 9  is a cross-sectional view of an alternate embodiment of the invention, shown after deforming the glass. 
       FIG. 10  is a sectional view of another alternate embodiment of the invention, shown after deforming the glass. 
       FIG. 11  is an isometric view of a lite according to an embodiment of the present invention. 
       FIG. 12  is a plan view of the lite of  FIG. 11 . 
       FIG. 13  is a cross-sectional view of the lite of  FIG. 11 , viewed along Section  13 — 13  of  FIG. 12 . 
       FIG. 14  is an isometric view of a door and a lite according to an embodiment of the present invention. 
       FIG. 15  is a cross-sectional view of the lite and a portion of the door of  FIG. 14 , viewed along section  15 — 15 . 
       FIG. 16  is an isometric view schematically illustrating a method of rolling artistic panes according to an alternative embodiment of the present invention. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   The present detailed description is generally directed toward devices, systems and methods for manufacturing artistic panes and windows and doors incorporating artistic panes. Specific details of certain embodiments of the invention are set forth in the following description and illustrated in  FIGS. 1–16  to provide a thorough understanding of the illustrated embodiments. One skilled in the art, however, will understand that the present invention may have additional embodiments, and may be practiced without several of the details described in the following description and illustrated in the figures. 
     FIGS. 1–4  illustrate an artistic pane  100  according to one particular embodiment of the present invention. In the illustrated embodiment, the artistic pane  100  is a pane of glass having a generally rectangular shape. The inventor appreciates, however, that the artistic pane  100  could be fabricated from other material and could have a wide variety of sizes and shapes, both without deviating from the spirit of the present invention. 
   The illustrated artistic pane  100  has a pair of opposing short sides  102  and a pair of opposing long sides  104 . The short sides  102  and the long sides  104  combine to form a rectangular margin  106  extending around the perimeter of the artistic pane  100 . The margin  106  is generally planar, and is sufficiently flat to be received in a traditional window frame or a came for a decorative window. As illustrated in  FIG. 2 , the margin  106  has a depth d from the respective side  102 / 104  inward toward a central portion  108  of the artistic pane  100 . In the illustrated embodiment, the depth d of the margin  106  measures approximately ⅛ inch, although the depth can vary to be suitable for a particular application, without deviation from the spirit of the invention. 
   As best illustrated in  FIG. 3 , the margin  106  has a thickness t between a top surface  110  and a bottom surface  112 . In the illustrated embodiment, the thickness t is approximately ⅛ inch, although the thickness can often be 3/16 inch, ¼ inch, ⅜ inch, or any other thickness suitable for a particular frame. 
   The central portion  108  is made up of a generally planar surface  114  that is broken up by a number of arbitrarily sized and shaped deformations  116 . As best illustrated in  FIG. 4 , the planar surface  114  is displaced laterally from the margin  106 , while the deformations  116  are displaced laterally with respect to the planar surface. In the illustrated embodiment, the deformations  116  are displaced from the planar surface  114  in the lateral direction of the margin  106 . The inventor appreciates, however, that the size, shape and direction of the deformations  116  can vary dramatically without deviating from the spirit of the invention. 
     FIG. 5  illustrates a device  120  for forming artistic panes according to one embodiment of the present invention. In the illustrated embodiment, the device  120  incorporates a support member  122  and a raised boundary member  124 . The support member  122  is made from a refractory material, such as ceramic. The illustrated support member  122  can be purchased under the brand name M-BOARD, produced by Thermal Ceramics of Augusta, Georgia. The inventor appreciates that other materials may be equivalent to the illustrated material, and that the support member  122  need not be one solid material, but could instead be laminated or otherwise coated with a refractory material. 
   The support member  122  in the illustrated embodiment has an upper surface  126  that is generally planar in shape. To modify the contour of an artistic pane according to the present invention, the inventor appreciates that the support member  122  can be molded or otherwise formed to create a relief that will transfer to the artistic pane when formed. The inventor appreciates that such modifications do not deviate from the spirit of the present invention, but would constitute equivalent embodiments thereof. 
   The raised boundary member  124  of the illustrated device  120  is planar in shape and is positioned against the upper surface  126  of the support member  122 . In the illustrated embodiment, the raised boundary member  124  is integrally formed on the support member  122 . The raised boundary member  124  may be built on top of the support  122 , or may be carved out of the support member. The inventor appreciates that, having reviewed this disclosure, one of ordinary skill in the art will appreciate the many equivalent means for forming the raised boundary member  124 . 
   The illustrated raised boundary member  124  has an upper surface  128  that is planar and flat. As described below, the upper surface  128  will ultimately form the margin  106  of the artistic pane  100 . 
   The raised boundary member  124  has an inner edge  130  that extends around the perimeter of a central portion  132  of the upper surface  126  of the support member  122 . In the illustrated embodiment, the inner edge  130  is rectangular in shape. The inventor appreciates, however, that the inner edge  130  can have a wide variety of shapes without deviating from the spirit of the invention. 
     FIG. 6  is an exploded view of a sheet of glass  129  and a device  220  for forming an artistic pane  100 , according to another embodiment of the present invention. The device  220  incorporates a support member  222  and a raised boundary member  224 . Similar to that described above, the support member  222  has a substantially planar upper surface  226 , and the raised boundary member  224  has a planar upper surface  228 . 
   The raised boundary member  224  in this embodiment is a separate and removable element of the device  220 . As such, the raised boundary member  224  can be moved and positioned with respect to the support member  222  as desired by the operator. In addition, the support member  222  can support several raised boundary members  224 , which can vary in size and/or shape, facilitating the mass production of artistic panes. 
   The raised boundary member  224  has an inner edge  230  that extends around a central opening  232 , which encircles a portion of the upper surface  226  of the support member  222  during use. In the illustrated embodiment, the inner edge  230  has rounded corners but, as discussed above, the shape of the inner edge can vary dramatically without deviating from the scope of the present invention. In the illustrated embodiment, the raised boundary member  224  is produced by Lydall out of Portsmouth, N.H., under the brand LYTHERM 1401. The illustrated raised boundary member  224  is ⅛ inch thick, although this dimension can vary as will be appreciated one of ordinary skill in the art. 
     FIGS. 7 and 8  illustrate one particular embodiment of the device  220  and a sheet of glass  229  according to an embodiment of the present invention. As shown in  FIG. 7 , the sheet of glass  229  is resting on top of the raised boundary member  224 , and is suspended above the upper surface  226  of the support member  222 . In the illustrated embodiment, the sheet of glass  229  is oriented with the tin side down. As discussed above, the upper surface  226  can be flat or can be shaped, as desired. An edge portion  234  of the sheet of glass  229  rests on top of the upper surface  228  of the raised boundary member  224 . The edge  234  of the sheet of glass  229  can terminate at the desired dimension for use as a window pane, or can be cut after processing to the desired size and shape. 
     FIG. 8  illustrates the sheet of glass  229  after being heated in an oven for a desired time and temperature. In the illustrated embodiment, the sheet of glass  229  is heated to a temperature above 1320° F. and, preferably, to a temperature above 1400° F. and, in some embodiments, to a temperature above 1500° F. In one embodiment, the temperature is between 1510° F. and 1535° F. At these temperatures, the sheet of glass  229  sags in the central opening  232  until it contacts the upper surface  226  of the support member  222 . The upper surface  228  of the raised boundary member  224  prevents the edge  234  of the sheet of glass  229  from sagging. Instead, because the upper surface  228  of the raised boundary member  224  is flat and planar, the edge  234  of the sheet of glass  229  remains flat and planar. The edge  234  of the sheet of glass  229  will ultimately become the margin  106  of the artistic pane  100 . 
     FIG. 9  illustrates a device  320  for forming artistic panes according to yet another embodiment of the present invention. In this embodiment, the device  320  is generally the same as that described above in connection with  FIGS. 7 and 8 . The device  320 , however, incorporates a curved mass  336  and a rectilinear mass  338  positioned within a central opening  332  between a sheet of glass  329  and a support member  322 . When the sheet of glass  329  is heated to the elevated temperature discussed above, the sheet of glass sags in the central opening  332 . In this particular embodiment, the curved mass  336  and the rectilinear mass  338  prevent portions of the sheet of glass  229  from contacting an upper surface  326  of the support member  322 . As a result the glass  329  is formed with round deformations  340  and flat deformations  342  in the area that will become a central portion of the artistic pane. 
     FIG. 10  illustrates still another embodiment of a device  420  according to still another embodiment of the present invention. This particular embodiment is similar to that illustrated in  FIG. 9 . In this embodiment, however, the device  420  incorporates a number of piles  444  of refractory particulates. The piles  444  are placed by the operator on the upper surface  426  of the support member  422  in one or more locations in the central opening  432  of the raised boundary member  424 . When the glass  429  sags into the central opening  432 , it will conform to the random and slightly deformable shape of the piles  444 . Thus, the ultimate shape of the artistic pane can be random and substantially unreproducible, creating an additional artistic effect. The size, shape and distribution of the piles  444  can be controlled as the operator desires. 
     FIGS. 11–13  illustrate a lite  500  or similar decorative window, according to one particular embodiment of the present invention. The illustrated lite  500  has a frame  502  that extends around the perimeter of the lite. The frame  502  can be selected from any number of frames available on the market. One of ordinary skill in the art, having reviewed this disclosure, will appreciate the types of frames that will be suitable for use with the present invention. 
   The illustrated frame  502  has an outer edge  504  and an opposing inner edge  506  extending around the entire perimeter of the lite  500 . The outer edge  504  is adapted to be inserted into a wall or door, as is generally understood in the art. The inner edge  506  is configured with a groove  508  extending around the perimeter of the frame  502 . The groove  508  is sized to receive a window  510  such as the decorative window illustrated in the present embodiment. 
   The window  510  incorporates a number of artistic panes  512  and other panes  514  assembled within the came assembly  516 . The size and shape of the artistic panes  512  and the other panes  514 , and the configuration of the came assembly  516  can vary dramatically based on user and/or customer desires. The exact configuration of the window  510  is not critical to the present invention beyond the incorporation of the artistic panes  512  into the assembly. 
   As best illustrated in  FIG. 13 , a margin  518  of the artistic pane  512  engages a came member  520  to form the window  510 . As discussed above, the margin  518  is planer and flat to allow the artistic pane  512  to fit within a came assembly  516 , even though the artistic pane incorporates a number of offset regions  522  and deformations  524 . 
   The window  510  is encased between a pair of opposing sheets of glass  526  to seal and/or protect the window  510 , or to increase the insulative properties of the lite  500 . The inventor appreciates that one of ordinary skill in the art, having reviewed this disclosure, will fully appreciate that the invention can be used with or without such sheets of glass  526 , and will fully appreciate how to incorporate sheets of glass into the assembly. 
     FIGS. 14 and 15  illustrate a door  600  having a lite  602  similar to that discussed above and shown in  FIGS. 11 and 12 . The lite  602  can be incorporated into the door  600  as generally understood in the art. The inventor appreciates that, having reviewed this disclosure, one of ordinary skill in the art will immediately appreciate that the inventive window and artistic pane can be incorporated into a wide variety of walls, doors, French doors and other configurations. 
     FIG. 16  schematically illustrates the method of forming artistic panes according to an alternate embodiment of the present invention. In the illustrated method, a roller  700  is configured with a number of dies  702  positioned to impart a desired shape onto a sheet of glass  704  as it moves past the roller  700 . As best illustrated in the enlarged portion of  FIG. 16 , each of the dies  702  has a margin area  706  and a central area  708 . The margin area  706  is raised with respect to the die  702 , and the central area  708  is recessed within the margin area of the die. Within the central area  708  are a number of raised areas  710 . 
   During use, when the die  702  molds the glass  704 , the margin area  706  creates a flat and planar edge for an artistic pane, that can be received within a frame as discussed above. The recessed central area  708  forms the laterally offset central region of the artistic tile, and the raised areas  710  form the deformations in the artistic tile. One of ordinary skill in the art, having reviewed this disclosure, will appreciate the structures and requirements necessary for forming artistic tiles through the rolling process. In addition, one of ordinary skill in the art, after reviewing the present disclosure, will appreciate that there are other equivalent processes for forming artistic tiles according to the present invention. 
   All of the above U.S. patents, U.S. patent application publications, U.S. patent applications, foreign patents, foreign patent applications and non-patent publications referred to in this specification and/or listed in the Application Data Sheet, are incorporated herein by reference, in their entirety. 
   From the foregoing it will be appreciated that, although specific embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the invention. Accordingly, the invention is not limited except as by the appended claims.