Abstract:
An apparatus and method for manufacturing glass objects comprising a glass blowing pipe and a metal mounting device configured to melt with glass to form a glass piece that is easily removed from the glass blowing pipe without the need to break the glass from the headstock of the glass blowing pipe, wherein the metal mounting device comprises a contact patch and a number of slits to secure the metal mounting device to the glass. A method for manufacturing a glass object utilizing a metal mounting insert is described. A glass object having a metal mounting insert for installation and use in other applications is also described.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     Applicant hereby claims priority under 35 U.S.C. §120 of co-pending U.S. non-provisional patent application Ser. No. 13/555,570 entitled GLASS BLOWING APPARATUS AND METHOD OF MAKING GLASS OBJECTS filed on Jul. 23, 2012, and which is incorporated herein by reference in its entirety. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention generally relates to the field of glass object manufacturing and more specifically to an apparatus for blowing glass objects and a method for manufacturing glass objects utilizing the glass blowing apparatus. 
     2. Background 
     Glass blowing is an age old practice going back hundreds of years. The method of blowing glass objects requires a glass blowing pipe capable of withstanding extreme heat to the point that sand/silica becomes a molten soup. The headstock of the glass blowing pipe is placed in the crucible containing molten glass, gathering the molten glass on the headstock of the pipe and coating it with molten glass. The hot molten glass adheres to the head stock. The artisan then removes the molten glass from the container and blows it into shape. As the piece is blown, the artisan has to create a weak spot between the head stock and the piece of glass being made. Once the piece is completed, the artisan separates the finished piece from the headstock by breaking the glass at the weak spot. The breaking process makes it easy for the piece to break beyond the weak spot and requiring the artisan to start the process from the beginning and blow a new piece. 
     The prior art discloses various head stock pieces that can be detached from the glass blowing pipe and which allow the replacement of the head stock without the need to replace the entire pipe. See, for example, U.S. Pat. Nos. 233,550; 268,162; 444,160; 976,796; 1,535,168; and 1,570,695. The headstock attachments disclosed in the prior art, however, do not solve the problem that arises from the need to break the glass in order to finish the piece. 
     SUMMARY OF THE INVENTION 
     The present invention provides a solution to the above and other problems by enabling a method of blowing of glass objects without the need to break the object at a weak spot to separate it from the head stock of the blowing pipe. It is one object of the present invention to provide a metal mounting device, comprising an attachment element and a contact patch. In some embodiments, the contact patch has a thickness of between 0.01 and 0.07 inches. In other embodiments, the contact patch has a thickness of between 0.009 and 0.125 inches. It is a further object of the present invention to provide a metal mounting device having a contact patch that comprises vertical slits. Preferably, the slits have a thickness of between 0.007-0.025 inches. In some embodiments, the vertical slits have a length of ⅕ the length of the contact patch. The contact patch in accordance with one object of the present invention is made from a material capable of melting with molten glass, preferably of a material with a coefficient of expansion equal or near to the coefficient of expansion of glass. In preferred embodiments the coefficient of expansion of the material is within five ten-thousands (0.0005) of an inch of the coefficient of expansion of the glass being used for manufacturing the glass blown object. In other preferred embodiments, the coefficient of expansion of the material is within fifteen ten-thousands (0.0015) of an inch of the coefficient of expansion of the glass being used for manufacturing the glass blown object. In yet further embodiments, the coefficient of expansion of the material is within ten ten-thousands (0.0010) of an inch of the coefficient of expansion of the glass being used for manufacturing the glass blown object. 
     In accordance with a further object of the invention, a kit for manufacturing glass objects having a glass blowing pipe configured to accept a metal mounting device and a metal mounting device comprising a contact patch is provided. In some embodiments, the kit further comprises a metal mounting device having a removal tool attachment element and a tool for removing the metal mounting device from the glassblowing pipe. In accordance with another object of the invention, the metal mounting device is configured to be removably attached to a headstock section of the glassblowing pipe. 
     A further object of the invention is to provide a method of blowing glass objects comprising the steps of gathering molten glass on a metal mounting device; and blowing a glass piece using the metal mounting device, wherein the metal mounting device comprises a contact patch. The method further comprises the step of removing the glass piece from a glass blowing pipe. A further step comprises attaching the glass piece to a mount. In yet a further embodiment, the method of claim comprises the step of attaching accessories to the glass piece, such as a light element. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other features, aspects, and advantages of the present invention are considered in more detail, in relation to the following description of embodiments thereof shown in the accompanying drawings, in which: 
         FIG. 1A  is a side view of the glass blowing pipe in accordance with one object of the present invention, wherein the pipe does not have a metal mounting insert attached to it. 
         FIG. 1B  is a sectional side view of the glass blowing pipe shown in  FIG. 1A . 
         FIG. 2A  is a side view of the glass blowing pipe in accordance with one object of the present invention with a metal mounting insert attached to it. 
         FIG. 2B  is a sectional side view of the glass blowing pipe shown in  FIG. 2 . 
         FIG. 3A  is a side view of a metal mounting insert for use with the glass blowing pipe in accordance with one object of the present invention. 
         FIG. 3B  is a sectional representation of the side view of  FIG. 3A . 
         FIG. 3C  is a top view of a metal mounting insert. 
         FIG. 3D  is a side view of a metal mounting insert with a release element. 
         FIG. 4A  is an illustration of the glass blowing pipe in accordance with one object of the present invention and the removal tool for removing a metal mounting insert having a release element. 
         FIG. 4B  is a sectional view of  FIG. 4A . 
         FIG. 5  is a flow chart of a method of blowing glass in accordance with one embodiment of the present invention. 
         FIG. 6A &amp; 6B  are illustration of various glass pieces attached to frames to form functional products. 
         FIG. 7  is an illustration of a metal mounting insert that includes lighting elements. 
         FIG. 8A and 8B  is an illustration of a glass object attached to a mount and secured by threads on the mount or a set screw. 
         FIG. 9  is an illustration of a glass object having more than one metal mounting insert. 
         FIG. 10  is an illustration of a glass object having a cap attached to the metal mounting insert. 
         FIG. 11  is an illustration of a glass object mounted to a metal housing and coupled to a water pump. 
         FIG. 12  is an illustration of a glass object with two metal mounting inserts to create a neon or fluorescent light. 
         FIG. 13A  is a side view of a metal mounting insert. 
         FIG. 13B  is a cross-sectional view of a metal mounting insert. 
         FIG. 13C  is a top view of a metal mounting insert. 
     
    
    
     DETAILED DESCRIPTION 
     The invention summarized above and defined by the enumerated claims may be better understood by referring to the following description, which should be read in conjunction with the accompanying drawings and claims in which like reference numbers are used for like parts. This description of an embodiment, set out below to enable one to build and use an implementation of the invention, is not intended to limit the invention, but to serve as a particular example thereof. Those skilled in the art should appreciate that they may readily use the conception and specific embodiments disclosed as a basis for modifying or designing other methods and systems for carrying out the same purposes of the present invention. Those skilled in the art should also realize that such equivalent assemblies do not depart from the spirit and scope of the invention in its broadest form. 
     In an effort to avoid the above-described disadvantages, a glass blowing pipe  100  is provided, as shown on  FIG. 1A and 1B . The glass blowing pipe  100  has three sections: a mouth piece section  105 , a pipe section  108 , and a headstock section  112 . The sectional view shown in  FIG. 1B  shows a more detailed view of the glass blowing pipe  100 . The glassblowing pipe  100  has an air channel  128  that runs from a distal end  133  at the end of the mouth piece section  105  through an insert end  135  of the headstock section  112 . 
     The configuration of the transition between the pipe section  108  and the head stock section  112  is not critical to the present invention. In some embodiments, the head stock section  112  is merely the end of the glass blowing pipe  100  that is opposite of the mouth piece section  105 , as shown on  FIG. 1 . In other embodiments, the headstock section  112  has a different configuration than the pipe section  108 . The headstock section  112  may be thicker, have a different shape, have a different surface, or be modified in any manner known to a person of ordinary skill in the art. In yet other embodiments, the headstock section  112  is removable from the pipe section  108 , as shown in the prior art. The headstock section  112  of the glass blowing pipe  100  has a pipe section end  120  and an insert end  135 , which corresponds to the distal end  135  of the headstock section as described above. The insert end  135  is configured to accept the metal mounting insert  115  as shown in  FIGS. 2A and 2B . 
     A metal mounting insert  115  is shown in  FIG. 3 . The metal mounting insert  115  is configured to attach to the headstock section  112  of the glass blowing pipe  100 . In a preferred embodiment, the metal mounting insert  115  is removably attached to the headstock section  112 . The metal mounting insert  115  as shown in  FIGS. 3A through 3D , has two sections: a glassblowing pipe attachment element  169  and a glass object attachment element  177 . In one preferred embodiment, as shown on  FIG. 3D , the glassblowing pipe attachment element  169  comprises insert threads  155  that allow the metal mounting insert  115  to be removably attached to the glassblowing pipe  100 . It is contemplated that the glassblowing pipe attachment element  155  is any type of release mechanism that allows tight fit between the glassblowing pipe  100  and the metal mounting insert  115 , resulting in minimum loss of air at the joint  121  between the distal end  135  of the headstock section  112  and the metal mounting insert  115 . 
     In one preferred embodiment, as shown on  FIGS. 1A and 1B , the distal end  135  of the head stock section  112  has head stock threads  139  that match insert threads  155  on the metal mounting insert  115 . The metal mounting insert  115  is screwed into the distal end  135  of the headstock section  112  as shown on  FIGS. 2A and 2B . The metal mounting insert  115  fits tightly in the head stock section  112  with minimal air escaping through the joint  121  between the head stock section  112  and the metal mounting insert  115 . It is contemplated that the metal mounting insert  115  can be mounted to the head stock section  112  by other methods that allow a tight fit that minimizes escape of air at the joint between the metal mounting insert  115  and the head stock section  112 . 
     In a further preferred embodiment, the metal mounting insert  115  has a release mechanism  195 . The release mechanism  195 , in some preferred embodiments, consists of an aperture on the metal mounting insert  115 . The aperture is configured to allow a removal tool  400  as shown on  FIG. 4 , to be inserted and aid in removal of the metal mounting insert  115  from the glassblowing pipe  100 . The removal tool  400  is turned counterclockwise to release the metal mounting insert  115  and the completed piece from the headstock section  112 . In preferred embodiments the coefficient of expansion of the metal mounting insert  115  is within five ten-thousands (0.0005) of an inch of the coefficient of expansion of the glass being used for manufacturing the glass blown object. In other preferred embodiments, the coefficient of expansion of the metal mounting insert  115  is within fifteen ten-thousands (0.0015) of an inch of the coefficient of expansion of the glass being used for manufacturing the glass blown object. In yet further embodiments, the coefficient of expansion of the metal mounting insert  115  is within ten ten-thousands (0.0010) of an inch of the coefficient of expansion of the glass being used for manufacturing the glass blown object. In some embodiments, the metal mounting insert is released from the pipe by clamping and unscrewing it with a normal pair of locking pliers. 
     The metal mounting insert  115  is fabricated from a material that fuses and anneals with molten glass. Thus, the metal mounting insert  115  is made from a material that has a coefficient of expansion near or equal to the coefficient of expansion of glass. Some of the materials used include copper, silver, gold or a metal with similar properties. Other materials include platinum, aluminum, iridium, palladium, nickel, osmium, and bronze. In some embodiments, bronze alloys of more than 90% copper can be used. When the glass and metal are super-heated, as in the glassblowing process, the materials bond and fuse together. The heat causes the materials to expand beyond size at room temperature. Though the metal and glass are fused at high temperature the materials shrink as they cool. As the metal mounting insert cools with the glass the two materials shrink back to their room temperature size. The rate at which the material, e.g. copper, expands when heated and the rate at which glass expands when heated are nearly matched. So when it cools back to room temperature they shrink at the same rate as well. If the metal and glass did not expand and contract at the same rate the glass would shrink faster than the metal and burst apart or the metal would lose its bond to the glass and simply slide off. If the coefficients of expansion match the glass and copper are bonded at a molecular level at any temperature. As a result, the cooling process is well controlled to avoid issues that may arise with the difference in the material&#39;s expansion coefficients. 
     A further embodiment of the present invention comprises a method of manufacturing glass pieces using a glass blowing pipe  100  and the metal mounting insert  115  described above. The method is described in the flowchart of  FIG. 5 . In a first step  500 , the metal mounting insert  115  is attached to the headstock section  112  of the glass pipe  100 . In a second step  505 , the metal mounting insert  115  is placed in the furnace and dipped directly into the crucible of molten glass. The molten glass gathers directly onto the metal mounting insert  115 . In a subsequent step  510 , once a sufficient amount of molten glass has been gathered upon the metal mounting insert  115 , the metal mounting insert  115  is rolled on a marver to ensure full and solid contact between the molten glass and the metal mounting insert  115  and to achieve desired shape. In a subsequent step  515 , additional molten glass is collected if necessary for a particular piece. In another step  520 , the glass piece is blown using the glass pipe  100 . In an optional step additional metal mounting insert&#39;s or spray inserts may be added to the finished glass piece. In a final step  520 , once the piece is finished it is unscrewed from the pipe with the metal mounting insert  115  permanently attached. 
     In a preferred embodiment of the present invention, as shown on  FIG. 6A , the completed piece is attached to a frame  610  to form a complex piece  600  with multiple individual pieces. The metal mounting insert  115  enables the piece to be attached to the frame  610  on any direction. In some embodiments, the piece is perpendicular to the frame  610 . In other embodiments the piece is placed on the frame  610  at various different angles. The metal mounting insert  115  may also be used to secure the glass blown object  609  to a mounting bracket  604  as shown in  FIG. 6B . In other embodiments, after the glass blown object  609  is attached to the mounting bracket  604 , an accessory is attached to the metal mounting insert  115 . By way of non-limiting example, the accessory can be a water coupling. The water coupling can be utilized to provide water to the glass blown object. 
     In another preferred embodiment, the metal mounting insert  115  is configured to fit a lighting element  710  as shown on  FIG. 7 . The lighting element  710  allows the glass blown piece  700  to be lit from the inside. Lighting elements include, but are not limited to, incandescent light bulbs, light emission diodes (LEDs), fluorescent light bulbs, Neon, high intensity discharge light bulbs, and other light emitting components as understood by a person of ordinary skill in the art. The light element  710  has a positive  757  and a negative  756  wire that enables electricity to be used in lighting the element  710 . In some embodiments a stopper  760  is used to secure the wires  757  and  756  and to prevent moisture to enter the metal mounting insert. In other embodiments, the metal mounting insert  115  is utilized to introduce other elements inside the glass piece. 
       FIG. 8A and 8B  show a metal mounting insert  115  attached to a glass blown object  800 , where the metal mounting insert  115  is attached to a mount  810 . In some embodiments, as shown in  FIG. 8A  the mount  810  has threads  820  that match the metal mounting insert  115  threads  155  so that the metal mounting insert  115  and glass blown object  800  can be screwed to the mount  810 . In other preferred embodiments, as shown in  FIG. 8B , the mount  810  does not have threads  820 . Instead, the mount  810  is configured to accept a set screw  815 , through a set screw opening  845 . The set screw  815  can be tightened to secure the metal mounting insert  115  to the mount  810 . In some embodiments the glass blown object shown in  FIGS. 8A and 8B  has a light emitting diode  710  can be inserted through the opening in the metal mounting insert  115 . It is contemplated that other accessories can be inserted through the opening in the metal mounting insert  115  that is mounted to the mount  810 . In yet a further embodiment, the mount  810  has threads  820  and a set screw  815 , which allows for further securing the metal mounting insert  115 . 
     In yet a further embodiment of the present invention, two or more metal mounting inserts  115  can be used, as shown in  FIG. 9 . A first metal mounting insert  115  is placed on one side of the glass blown object  900  and a second metal mounting insert  115  is placed on a different place in the glass blown object,  900 . The first metal mounting object may include a metal mounting accessory  920 . The metal mounting accessory  920 , in some embodiments, may include ornamental features or functional features. In one embodiment, the metal mounting accessory is a water spout. The glass blown object  900 , in some embodiments is attached to a mount  910  that, in turn, is attached to a coupling  915  for a water pipe  950 . Water passes from the water pipe  950  to the glass blown object  900 , and out through the metal mounting accessory  920 . 
     In yet further embodiments of the present invention, as shown on  FIG. 10 , a cap  1000  can be screwed to the metal mounting insert  115 . It is contemplated that other accessories may be added to the metal mounting insert. 
     In yet a further embodiment of the present invention, a kit for manufacturing glass blown objects comprises a glass blowing pipe and a metal mounting insert. In further embodiments, the kit contains a metal mounting object removal tool. In yet further embodiments, the kit comprises accessories, mounts, mounting brackets and other components described above to manufacture glass pieces with a metal mounting insert. 
     In yet further embodiments of the present invention a glass blown object  1100  has a metal mounting insert  115  as shown on  FIG. 11 . The metal mounting insert  115  connects with a coupler  1125 . The coupler  1125  is attached to a water pump  1110  through a supply tube  1120 . The water pump  1110  is attached to a vessel  1105  in a housing  1115 , which in some embodiments is a metal casing. When the glass blown object  1100  is connected to the coupler, water  1106  is pumped through glass blown object  1100  and falls on the vessel creating a fountain where water  1106  is recirculated. 
     In yet further embodiments of the present invention, as shown on  FIG. 12 , light emiting object  1200  is made by adding two metal mounting inserts  115  to a glass blown object. A first metal mounting object  115  has an anode  1211 . The second metal mounting object  115  has a cathode  1210 . One metal mounting object  115  has a cap  1215  and the other may connect to a socket  1205  that allows electricity to be passed through the anode  1211 . The light emitting object  1200  is vacuum sealed and includes a gas that produces light when electricity is applied to the anode  1211  and cathode  1210 . 
     It is contemplated that the metal mounting insert  115  can be utilized in a traditional glass blowing pipe or any other device that allows for blowing glass objects either by hand or automatically. When the metal mounting insert is attached to an automatic blowing device, the metal mounting insert is removed from the blowing device and remains as part of the glass blowing object. 
       FIG. 13  shows an improved metal mounting insert  115  for use with glass blowing pipe. The improved metal mounting insert  115  includes a contact patch  1301 , which is designed to provide a more reliable attachment to the glass. The contact patch  1301  has a reduced the wall thickness when compared to the body  1305  of the metal mounting insert  115 . The contact patch  1301  is the area of metal that fuses with the glass, it reduces checking and fracturing through the fusion process and reduces failure rate. Optimal wall thickness around the contact patch preferably ranges approx. between 32-15 gauge or 0.01-0.07 inches depending on the application and size of the metal mounting insert  115 . It is contemplated that the metal mounting insert  115  can be as thin as 0.009 inches and as thick as 0.125 inches. 
     In one preferred embodiment, vertical slits  1312  are cut into the contact patch  1301  of the metal mounting insert  115 . The vertical slits  1312  prevent the glass from cracking around the metal rim of the metal mounting insert  115  during the cooling process also reducing failure rate. In some embodiments, vertical slits have a thickness of between 36-22 gauge, or 0.007-0.025 inches. The length of the vertical slits  1312  may also vary, in some embodiments the length of each vertical slit  1312  is approximately ⅕ the length of the contact patch  1301 . Typically, the vertical slits  1312  are shorter than the length of the contact patch  1301 . In some preferred embodiments, the distance between each slit  1312  ranges between 0.125-0.75 inches. It is contemplated that there may be as many, or as few, slits  1312  as required for securing the glass to the metal mounting insert  1312 . In some embodiments 2, 3, 4 or 5 slits  1312  may be utilized. The number of slits  1312  can be adjusted based on the size of the metal mounting insert  1312 . 
     The invention has been described with references to a preferred embodiment. While specific values, relationships, materials and steps have been set forth for purposes of describing concepts of the invention, it will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the spirit or scope of the basic concepts and operating principles of the invention as broadly described. It should be recognized that, in the light of the above teachings, those skilled in the art can modify those specifics without departing from the invention taught herein. Having now fully set forth the preferred embodiments and certain modifications of the concept underlying the present invention, various other embodiments as well as certain variations and modifications of the embodiments herein shown and described will obviously occur to those skilled in the art upon becoming familiar with such underlying concept. It is intended to include all such modifications, alternatives and other embodiments insofar as they come within the scope of the appended claims or equivalents thereof. It should be understood, therefore, that the invention may be practiced otherwise than as specifically set forth herein. Consequently, the present embodiments are to be considered in all respects as illustrative and not restrictive.