BACKGROUND OF THE INVENTION
Field Of The Invention
[0001] This invention relates to simulated stained glass and, in particular, to simulated
stained glass having a high degree of color shading and striations and tonal and texture
variations, useful for simulation of stained and leaded glass.
Brief Statement Of The Prior Art
[0002] For many years, artisans have attempted to simulate stained and leaded glass using
various materials and methods. While lead caming can be simulated with lead strips
which are adhesively bonded to a sheet of glass, a wide variety of materials and methods
have been used in attempts to simulate stained glass. Stains or paints, and a texturing
resin have been coated on glass in U.S. Patent 2,713,958; a color printed polyester
film has been laminated between two preformed plastic shades to simulate a Tiffany
lamp shade in U. S. Patent 3,876,483; a color printed transparent paper has been laminated
between translucent sheets to simulate stained glass in U.S. Patent 2,190,627; colored
varnishes have been applied to the edge, and permitted to drain across a sheet of
glass in an attempt to simulate art glass in U.S. Patent 2,095,402; glass has been
painted using stencils and an air brush in U.S. Patent 1,800,763; and oven-cured,
translucent and colored varnishes have been used in U.S. Patents 744,209 and 696,392
to simulate art glass. A common problem with most of the prior attempts, particularly
those using paint or stains applied directly onto glass is the susceptibility of the
color coatings to marring and scratching. For this reason many of the aforementioned
patents also include the application of a protective layer of clear glass or plastic
which is laminated over the color coatings, e.g., see U.S. Patent 4,194,669 and French
patent 2,486,878.
[0003] None of the aforementioned methods have been commercially successful. In two recent
patents, U.S. Patent 4,438,165 and 4,335,170 a method is described in which sheets
of colored polyester film corresponding to a color pattern are applied onto a sheet
of glass and their boundries delineated with adhesive strips of lead to simulate stained
and leaded glass. The polyester film is painted, usually with a silk screening method
to simulate stained glass colors. This method has been so successful that it has been
recognized as a new art form.
[0004] Stained glass, however, has an extremely varied color shading and texture. Perhaps
the most exquisite is antique glass which is hand blown into a tubular shape, split
and flattened into panes which have bubbles, and color imperfections that provide
uneven shading with much variation in color tone and texture. There is also flash
or opalescent glass which is hand blown glass obtained by dipping molten globs of
colored glass into differently colored molten glass. The multiple colored layers provide
veining and an opalescent quality to the glass. Finally, there is machine rolled glass
which is of constant thickness and of comparatively uniform color shading.
[0005] The painted polyester films, particularly the silk screen painted films, can quite
accurately simulate the appearance of the machine rolled glass, however, heretofore,
there has been no method of coloring the polyester film that achieves the degree of
color shading and striations, and the tonal and texture variations of antique and
flash or opalescent glass.
BRIEF DESCRIPTION OF THE INVENTION
[0006] This invention comprises a method, and apparatus used in the method, for painting
plastic film with translucent and transparent colorants which achieves a high degree
of variation in color tones, shading, and striations, and which also can impart texture
variation to the film. The plastic film is adhesively bonded to a sheet of glass,
thereby simulating stained glass. The method of the invention is practiced by the
application of a plurality of colorants to a surface of the film. Each colorant comprises
a liquid carrier which is compatible with the surface of the film and a pigment or
dye of a color which is distinct from that of the other colorants which are used.
The proportions of liquid carrier and pigment or dye can be adjusted as necessary
or desired to impart any degree of translucence or opaqueness to the plastic film.
when the colorant is too concentrated, it can be applied as a wash. The colorants
are wiped across the surface of said film by dragging a wiper blade across said surface
of said film predominantly along one direction while oscillating the wiper in a lateral
direction. The excess colorants are drained from said surface of said film and permitted
to to dry; and the said plastic sheet is then adhesively bonded to the surface of
a sheet of glass.
[0007] Preferably, deposits of thick colorant gums are randomly applied to the plastic film
prior to wiping of the colorant washes, thereby forming opalescent color inclusions
in the resultant color coating. These gums are preferably partially cured compositions
of pigments in a film forming vehicle.
[0008] The apparatus of the invention comprises a table for holding the plastic film and
retaining the colorant washes during the application of the colorants to the film.
The table comprises a flat bed to support the film and a movable retainer which can
be raised from, and lowered, to the bed with a peripheral masking strip that seals
against the edges of the plastic film.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The invention will be described with reference to the drawings, of which:
FIGURE 1 illustrates the step of applying the colorants to the plastic film;
FIGURE 2 illustrates the step of wiping the colorants across the plastic film;
FIGURE 3 illustrates the application of a colorant concentrate to the plastic film;
FIGURE 4 illustrates a typical application of the colored plastic films to a glass
pane to simulate stained and leaded glass;
FIGURE 5 is an elevational side view of the table used to apply the colorants;
FIGURE 6 is a top view of the table; and
FIGURE 7 is an elevational end view of the table.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0010] Referring now to FIGURE 1, the invention is practiced by applying a plurality of
colorants, 10, 12 and 14, to the surface of a plastic film 16. The film 16 is of a
suitable transparent or translucent plastic such as polyester, polyvinyl chloride,
polyvinyledene chloride, cellulose acetate, polyvinyl alcohol, polyvinyl acetate,
etc. The preferred plastic for the application to glass to simulate stained glass
is polyester, because it is significantly more compatible as a film coating on glass
than are the other plastic materials. The film should have a thickness from 0.5 to
about 5 mils, and preferably is completely flexible.
[0011] The colorants comprise a film former vehicle or carrier in which organic dyes are
dissolved or in which inorganic pigments are suspended, together with sufficient solvent
to achieve the desired viscosity. Preferably, a polyester vehicle is used when the
colorants are to be applied to a polyester film, and suitable polyester film formers
which can be used for this purpose are terephthalate esters of polyols such as ethylene
glycol, propylene glycol, etc. A preferred film former is ethylene glycol terephthalate.
These colorants are commercially available as as polyester inks and stains concentrates,
and typically contain from 35 to 65 weight percent solids. In some instances, the
colorant concentrate will render the plastic film opaque, and in such instances, the
colorant is applied as a wash and is obtained from its concentrate by the addition
of thinner, or let down base, in proportions of from 1 to 10 parts thinner per part
of concentrate.
[0012] The pigments which can be employed in the liquid colorant compositions can be organic
or inorganic finely subdivided solids. The inorganic pigments include oxides and salts
of metals such as titanium, iron, lead, zinc, cadmium, mercury, chrominum, molybdenum,
etc. Titanium dioxide in both anatase and rutle crystal form is the predominant white
pigment. Iron oxides are used for red, brown and tan colors; lead chromate is used
for yellow, lead molybdates for orange, red and related colors, and mixtures can be
prepared for varied shades of orange. Lead chromate is also combined with iron blue
(ferric ferrocyanide) to prepare green colorants. The cadmium salts and oxides are
used for red, maroon and yellow shades and other salts include the aluminates such
as cobalt aluminate or titanates such as chromium titanate.
[0013] Organic pigments or dyes which can be used include azo compounds which have one or
two azo linkages to provide orange, yellow and red colorants. The azo groups are typically
in aromatic compounds which include naphthol, or toluidine groups. Some of the azo
pigments include chelate metals, e.g., chelated nickel yellow. Another class of organic
colorants are the phthalocyanine greens and blues. Colors of red, maroon, and violet
can be obtained with the quinacridone pigments. The isoindolinones are a group of
pigments in the red to yellow range which can be used. The anthraquinones such anthraquinone
red, indathrone blue, anthra pyrimidine yellows are also suitable for use.
[0014] Special color effects can also be imparted to the colorants. These effects include
the metallics in which finely subdivided metal powders such as aluminum and aluminum
alloys are used to product brilliant blue-white highlights and copper and copper alloys
with zinc are used to produce gold and bronze highlights. These can be admixed with
the dyes or organic or inorganic pigments to impart a metallic luster to the plastic
film. The pigments and dyes are used in effective amounts, depending on the particular
pigment or dye which is employed. When dilute washes are used, particularly in combination
with the use of colorant gums, hereinafter described, the pigment or dye can be used
in low concentration, typically from about 0.1 to about 10 weight percent. In most
other applications, however, the colorant is used in more concentrated colorants,
typically at concentrations from 5 to about 55 weight percent.
[0015] The film 16 is laid onto a supporting surface, such as table 18, and the colorants
are applied to its exposed surface 20 in excess amounts. In the preferred method,
a retainer frame 24 having sidewalls 26 and 28, and end walls 30 and 32. is seated
over the peripheral edges of the film 16 and sealed thereto to provide retention of
the liquid colorants. At each end, and preferably also along each side, the frame
24 has a wide, flat web 25 to receive the colorants. A plurality of colorants 10,
12 and 14 are applied, preferably to the flat web 25 of the frame, usually at points
such as 11, 13, and 15 which are laterally offset along the width of film 16. It is
preferred to apply the colorant concentrates to the frame 24, rather than directly
to the plastic film, to avoid any undesired stain pattern on the film. The colorants
are contained within the general area of the film by the retainer frame 24 and the
flat perimeter web 25 receives the excess colorants. The concentration of the pigment
or dye in each colorant is determined by separate application of the colorant to test
strips of the plastic film. When the concentrate as commercially obtained renders
the plastic film too opaque, it can be thinned by the addition of let down base.
[0016] Referring now to FIGURE 2, the colorants are then wiped across the surface of the
film 16 with a wiper means such as a squeegee 34 having a wiper blade 36 formed of
a flexible plastic or rubber and a handle 38 for grasping by the operator. The squeegee
34 is moved along a first, predominant direction, indicated by arrow headed line 40
while it is oscillated laterally, from side to side, thereby obtaining undulating
striations of colorant on the surface of the film 16. The colorants blend together
at their interfaces, as represented by the broken lines, producing areas such as 33
and 35 of blended colors of varying intensity, separated by thin bands such as 37
which are mostly of the respective colorant, such as 12. The resulting pattern of
the colorants will be mostly veined along the predominant direction of the squeegee
34. The colorants will be most intense at the positions closest to their application
to the film 16 and the intensity will fade as they are dragged across the film. The
operator also controls the texture of the film by variation of the angle of repose
of the wiper blade 36 to the surface of film 16; as this angle is lessened, the thickness
of the colorant layer increases, while minimum color intensity and thickness of the
colorant layer is achieved when the wiper blade 36 is nearly vertical to the surface
of film 16.
[0017] The excess amounts of the colorants are wiped from the surface of the film 16 and
deposited on the peripheral ledge 25 which surrounds the film 16. The wiping across
the surface of the film 16 can be practiced by the operator as many times as desired
to achieve exactly the coloration and texture desired. Repeated wiping, will reduce
the degree of color tonal and texture variations, and often the most desirable effects
are achieved with only a single pass with the squeegee over the film 16.
[0018] The film 16 is removed from the table, and permitted to air dry, usually for a period
of several hours to several days, depending on the composition of the colorants, particularly
on the identity of the film former and any solvent used in the colorants. After drying,
the film 16 is ready for application to a glass surface. Preferably, the film 16 which
is selected for use in the invention has its undersurface coated with a continuous
coating of a pressure sensitive, permanent adhesive, and this coating is protected
with a removable overlay film. The plastic films which have been previously mentioned
are available precoated with suitable permanent adhesives from their manufacturers,
and these are preferably used to avoid the necessity to apply a continuous coating
of adhesive to the undersurfaces of the films.
[0019] FIGURE 3 illustrates a preferred method in which at least one colorant concentrate
46 is applied to one or more spot locations of the film 16. The concentrate can be
applied with a spoon 48 and the concentrate is deposited as a glob 47 and dragged
across the film with the spoon.
[0020] A preferred embodiment of the invention utilizes colorant gums of thick consistencies.
The gums are partially cured colorants, in which the film formers in the colorants
have been permitted to partially cure, usually by air drying or exposure. The resultant
gums are subdivided into globs of concentrated colorants usually in amounts from 5
to about 100 grams, preferably from 10 to about 45 grams, each. The resultant globs
can be used as the concentrate 46 shown in FIGURE 3 and are thereby applied directly
onto the surface of the film 16 at preselected locations. The globs such as 46 are
included within the coatings which are formed on the film 16 during the wiping step.
Because the gums are partially cured, they do not completely disperse in the liquid
colorants, but remain, distinct in color and texture from the colorant coating, thereby
producing opalescent effects with surface imperfections.
[0021] In the assembly of a simulated stained and leaded glass pane, the pane 50 (shown
in FIGURE 4) is first scrupulously cleaned and a decorative design 52 is drawn directly
upon the pane 50. Alternatively, a design drawn on paper may be temporarily taped
to the reverse side of pane 50. Next, adhesively backed lead strips 60 are applied
to the pane, to overlie the line tracing of the design. The adhesive can be applied
to the lead, and for this purpose, an acrylic adhesive is preferred. The lead strips
are commercially available with adhesive coatings on their undersurfaces and these
are preferably used in the simulation of lead caming. The lead may be stretched to
remove any kinks and undesired bends and is then laid upon the front side 61 of the
pane 50 covering the previously drawn lines of the design. A wooden tool, not shown,
having a concave contour similar to the convex exposed side of the lead strips 60
is preferably utilized to urge the lead strips 60 firmly onto the pane 50 thus removing
all entrapped air pockets and sealing the edges of the strips 60. Excess adhesive
may be removed by wiping with a solvent, which can also remove any oxidation from
the lead strips 60.
[0022] The film 16 is applied to the surface 53 of a glass pane 50 to simulate the appearance
of stained glass. The sheet of film 16 must be chosen which equals or exceeds the
dimensions of the design section 55 to be colored. As previously mentioned, films
16 which are precoated with a permanent, pressure sensitive adhesive are preferably
used. Alternatively, however, a permanent adhesive can be sprayed, brushed or rolled
onto the underside 51 of the film 16.
[0023] A lubricant, preferably a soap solution, is sprayed onto the adhesive undersurface
of the film 16 to neutralize the adhesive and permit the film 16 to be slid about
the surface 52 of glass pane 50 to be positioned at the appropriate design segment
55. The film can be pretrimmed, if desired; however, it is preferably trimmed on the
glass pane 50 with a razor blade or knife. The soap solution is then removed by pressing
the film 16 firmly against the pane 50 with a squeegee or similar tool, and permitting
the adhesive 51 to permanently bond the film 16 to the pane 50. Thereafter, lead strips
60 can be applied to the side 53 of the glass pane 50, completing the simulation of
stained and leaded glass.
[0024] The coating of the film 16 with the colorant in accordance with the method of the
invention is preferably practiced with the table which is illustrated in FIGURES 5-7.
Referring to FIGURE 5, the table 63 has a base 69 with legs 65 at each corner, and
frame 24 is moveably positioned on the table 61 with lift means which can raise and
lower the frame relative to the table. A convenient lift means is a centrally positioned
pnuematic or hydraulic lift cylinder 67. The base of the cylinder 67 is mounted on
the base 69, and the upper end of the piston rod 68 is secured with nut 64 to a crossed
arm brace 75 which is formed of metal channels 76 (shown in phantom lines in FIGURE
6) which extend diagonally outwardly from the center of the table. Rods 77 are vertically
mounted in distal bores in each of the metal channels 76 and fasteners such as locknuts
70 and 71 are secured to the threaded ends of rods 77 to clamp against opposite sides
of the metal channels, thereby firmly securing the rods.
[0025] The table legs 65 support the table 61 which has apertures at each corner in which
are secured bearing mounting plates 70. The rods 77 pass upwardly through the bearing
mounting plates and linear bearings 73 are mounted about the rods and seated in the
bearing mounting plates 70. The table also supports a central, raised island 66 which
has the dimensions to correspond to the area of the plastic film which is to be colored.
[0026] At their upper ends, rods 77 support the masking frame 24; see also FIGURES 1-3 amd
6. Frame 24 has a central, square aperture 81 and an outer peripheral retainer frame
82 formed of side walls 26 and 28, and end walls 30 and 32. FIGURE 7 illustrates the
cross section of the retainer frame 82 which is formed with the outer members such
as 84 having a raised outside edge 85; coextensive flat members 86, which are secured
thereto by suitable means such as fastener screws 87; and a coextensive metal masking
strip 91 in the form of an angle member is secured along the inside edges of the flat
members 86 with screw fasteners 82. Preferably the masking strip has a downward inclination
to its flat edge 92 which is from 3 to about 10 degrees off the horizontal.
[0027] Referring now to FIGURE 6, the flat edges 92 of the masking strips 91 extend about
the inner periphery of the aperture 81 of the masking frame 24 and extend inwardly
sufficiently to overlie the peripheral edges of the island 66 of table 61. When the
masking frame is retracted against table 61, the flat edges 92 of masking strips 91
are pressed against the top peripheral edges of island 66 and securely retain plastic
film 16 on the island. In this position, any excess colorants wiped from the plastic
film 16 will be deposited on the flat webs of the flat members 86, removed from the
plastic film. The excess colorants can be again moved across the surface of the film,
as desired by the operator. When the operator has completed a satisfactory color pattern
on the plastic film, the masking frame is raised above the table, and the plastic
film can then be lifted from the island 66 of the table and placed to dry. The raising
and lowering of the masking frame can be controlled by a suitable hand lever 82 which
operates a valve in the air or hydraulic fluid supply to cylinder 76.
[0028] Any other suitable means can be used to raise and lower the masking frame, such as
overhead pulleys and cables. It is desirable that the frame be raised in a horizontal
position, so the excess colorants on the flat web 25 do not drain onto the film 16
or the floor.
[0029] The invention provides a simple direct procedure to simulate stained glass having
variations and graining in its color tones. It achieves such variations and graining
without use of printer screens such as commonly used in silk screen printing. In fact,
such screens, which are commonly placed over the work, and beneath the squeegee, will
not function properly with this method, as the direct application of concentrated
colorants to such screens will clog the screens, resulting in uncolored areas in the
areas where the concentrated colorants were applied. The method of using the masking
frame provides a very convenient manner of handling the colorants, which are applied
in excess, as the excess is wiped across the film and removed from the film during
practice of the method. The masking frame provides areas immediately adjacent.to the
film to receive the application of the colorants and to receive the excess colorants.
The method of applying the colorants onto the frame, rather than directly onto the
film avoids color spots which could otherwise be formed at the points where the colorants
are poured directly onto the film. The gums, which are partially cured colorants,
have a limited solubility with the colorants, which mutes or softens their contrast
to the surrounding colorants, while maintaining distinct or marked concentrations
of the colorant. This closely simulates the imperfections in antique or opalescent
glass.
1. A method for simulation of antique colored glass which comprises:
(a) selecting a plastic film having a thickness from 0.5 to aout 5 mils;
(b) coating a continuous layer of a permanent, pressure sensitive adhesive onto one
surface of said film;
(c) applying, to the opposite surface of said film, a plurality of colorants, each
comprising a liquid carrier which is compatible with the surface of said film and
a pigment or dye of a color distinct from that of the other colorants of said plurality
of colorants;
(d) wiping said plurality of colorants across the surface of said film by placing
a wiper blade directly onto the surface of said film, and dragging, generally in a
first predominant direction, said wiper blade across said surface of said film, while
oscillating said wiper blade in a lateral direction;
(e) draining the excess of colorants from said surface of said film and permitting
said colorants to dry; and
(f) applying said plastic sheet, with its adhesive surface, against the surface of
a sheet of glass.
2. The method of claim 1 including the step of applying to said other surface of said
glass, in a random pattern, deposits of thick, gummy colorants prior to said wiping
step.
3. The method of claim 2 wherein said deposits are partially cured compositions of
pigments in a film forming vehicle.
4. The method of claim 1 wherein said plurality of colorants are applied at laterally
spaced-apart locations on said film.
5. The method of claim 4 wherein said plurality of colorants are applied with a squeegee
and the thickness of the colorants applied to said film is controlled by regulation
of the angle of the wiper blade of said squeegee against said film.
6. The method of claim 1 wherein said colorants comprise from 35 to about 65 weight
percent pigment in a film former carrier.
7. The method of claim 1 wherein said colorants comprise a wash formed of a colorant
containing from 35 to about 65 weight percent pigment in a film former carrier and
diluted with from 1 to 10 parts of a soluble thinner per part 5 of colorant.
8. The method of claim I wherein said film is placed on a work table and a frame with
upright sidewalls and a masking frame is placed over the edges of said film, including
the steps of pouring said colorants onto preselected areas of said masking frame and
dragging said colorants from said masking frame onto said film.
9. The method of claim 8 wherein said colorants are applied in excess, and the excess
amounts of colorants are dragged across said film and deposited on said masking frame.
10. A table for coloring plastic sheet material which comprises:
(a) a work table surface;
(b) a work island centrally positioned and rigidly secured onto said work table surface
and raised above the level thereof;
(c) a peripheral frame having outer dimensions substantially corresponding to the
outer dimensions of said work table surface, and a central aperture with dimensions
substantially corresponding to the outer dimensions of said work island;
(d) lift means attached to said table with lift arms extending therefrom to said peripheral
frame to support said frame above said work table surface;
(e) lift actuation means to move said peripheral frame between an elevated position
above said work table surface and a lower position resting on said work table surface;
and
(f) masking frame means carried by said frame peripherally about said central aperture
of said frame to engage the upper peripheral edge about said work island when said
frame is in its lowered position, thereby securing and masking a film or sheet material
overlying said work island.
11. The table of claim 10 wherein said frame has a vertical fence surrounding a lateral
horizontal masking surface.