Architectural glass panels with embedded objects and methods for making the same

Abstract

A decorative architectural glass panel comprises a two or more glass sheets separated by a resin in which one or more decorative objects are suspended. A method of making the glass panel comprises positioning one or more spacers and one or more decorative objects on a first glass sheet, placing a second glass sheet about the first glass sheet, sealing the edges of the first glass sheet and second glass sheet, and filling the space between the first and second glass sheets with a curable liquid resin. The resin can be poured using a substantially horizontal pour in order to keep the decorative objects from substantially shifting when pouring the liquid resin. The resin can also be poured in combination with a vacuum force. In some implementations, the glass panel may also be substituted with a resin panel using polymeric resin sheets.

1 . A decorative architectural panel comprising: 
 a first glass sheet positioned opposed to a second glass sheet in a registered fashion; and    plurality of decorative objects suspended in a cured resin between the first and second glass sheets.    
   
   
       2 . The glass panel as recited in  claim 1 , wherein at least one of the first and second glass sheets are flexible, such that the first and second glass sheets bend toward each other about the one or more decorative objects as the resin cures.  
   
   
       3 . The glass panel as recited in  claim 1 , wherein the space between the first and second glass sheet is filled by the cured resin at about ⅛ to ½ inches  
   
   
       4 . The glass panel as recited in  claim 1 , wherein the first and second glass sheets are each from about 3 feet wide to about 6 feet wide; and from about 5 feet long to about 10 feet long.  
   
   
       5 . The glass panel as recited in  claim 1 , wherein the first and second glass sheets are each from about 4 feet wide to about 6 feet wide; and from about 13 foot long to about sixteen feet long.  
   
   
       6 . The glass panel as recited in  claim 4 , wherein at least the first glass sheet is about ⅛ inches or greater in gauge.  
   
   
       7 . The glass panel as recited in  claim 1 , wherein the plurality of decorative objects comprise three-dimensional organic objects that appear to be uncompressed from a natural state, such that the plurality of decorative objects substantially project the appearance of natural dimensions.  
   
   
       8 . The glass panel as recited in  claim 7 , wherein the plurality of decorative objects comprise naturally-occurring objects that have each been treated on its entire surface with a preserving resin that provides a barrier with the cured resin between the first and second glass sheets.  
   
   
       9 . A sheet assembly for use in creating a decorative architectural panel comprising: 
 a first sheet comprising one or more spacers positioned on a surface thereof;    one or more decorative objects positioned on the first sheet surface;    a second sheet overlaid with the first sheet in a registered fashion, such that the one or more decorative objects are positioned throughout an interspace region defined by the first and second sheets;    blocking means positioned about a peripheral edge of the sheet assembly;    a sealant positioned about the blocking means; and    a liquid resin poured between the first sheet and the second sheet, wherein the liquid resin comprises a layer between the first sheet and the second sheet that is at least one-eighth inch thick when cured.    
   
   
       10 . The sheet assembly as recited in  claim 9 , wherein the first sheet and the second sheet comprise a polymeric resign selected from the group consisting or polyester resin, polycarbonate resin, acrylic resin, and mixtures thereof.  
   
   
       11 . The sheet assembly as recited in  claim 9 , wherein the sealant comprises any one of a silicone-based sealant, a urethane-based sealant, and mixtures thereof.  
   
   
       12 . The sheet assembly as recited in  claim 9 , wherein the one or more decorative objects have been treated with a UV-curable resin configured to preserve coloration of organic material within the liquid resin.  
   
   
       13 . The sheet assembly as recited in  claim 9 , wherein the one or more spacers comprise a tape having sufficient thickness to separate the first and second glass sheets about the one or more decorative objects.  
   
   
       14 . The sheet assembly as recited in  claim 9 , wherein the first sheet and the second sheet comprise glass.  
   
   
       15 . The sheet assembly as recited in  claim 14 , wherein at least one of the first sheet and the second sheet comprise flexible glass, such that the first and second glass sheets bend toward each other about the one or more three-dimensional objects as the resin cures.  
   
   
       16 . The sheet assembly as recited in  claim 9 , wherein the one or more decorative objects comprise any synthetic, manufactured, or naturally-occurring representations of vegetable fruits, rocks, minerals, crystals, vegetative brush, branches, thatch, grasses, or willow reed.  
   
   
       17 . The sheet assembly as recited in  claim 16 , wherein the one or more decorative objects comprise a plurality of un-compressed three-dimensional objects positioned randomly within the space defined by the first and second sheets.  
   
   
       18 . (canceled)  
   
   
       19 . (canceled)  
   
   
       20 . (canceled)  
   
   
       21 . (canceled)  
   
   
       22 . (canceled)  
   
   
       23 . (canceled)  
   
   
       24 . (canceled)  
   
   
       25 . (canceled)  
   
   
       26 . (canceled)  
   
   
       27 . The glass panel as recited in  claim 1 , wherein the plurality of decorative objects are randomly positioned throughout the first and second glass sheets in the cured resin.  
   
   
       28 . The glass panel as recited in  claim 1 , further comprising: 
 a third and fourth glass sheet positioned opposed to the first or second glass sheets in a registered fashion; and    one or more second decorative objects suspended in a curable resin between the third and fourth glass sheets.    
   
   
       29 . The glass panel as recited in  claim 8 , wherein the preserving resin is a UV-curable resin that is liquid at room temperature.  
   
   
       30 . The sheet assembly as recited in  claim 9 , wherein the blocking means comprise a sealant-impermeable material including any of tape or plastic wrap.  
   
   
       31 . The sheet assembly as recited in  claim 9 , wherein the blocking means are positioned on each outside edge of the laminate assembly.  
   
   
       32 . The sheet assembly as recited in  claim 9 , wherein the blocking means are positioned between each of the one or more spacers, such that the one or more spacers can be removed from between the blocking means.  
   
   
       33 . The sheet assembly as recited in  claim 9 , wherein the first and second sheets comprise textured resin sheets.  
   
   
       34 . The sheet assembly as recited in  claim 9 , wherein the liquid resin has a cure time of greater than 16 hours at room temperature.  
   
   
       35 . The sheet assembly as recited in  claim 9 , wherein the first sheet is positioned horizontally on the surface, such that the second sheet is horizontally registered with the first sheet.  
   
   
       36 . The sheet assembly as recited in  claim 9 , further comprising: 
 a third sheet and a fourth sheet overlaid with any of the first or second sheet in a registered fashion; and    one or more second decorative objects positioned between the third and fourth sheets, and encapsulated by the liquid resin;    wherein the one or more decorative objects comprise a first object layer, and the one or more second decorative objects comprise a second object layer.    
   
   
       37 . The sheet assembly as recited in  claim 36 , wherein the one or more decorative objects are different in composition from the one or more second decorative objects, such that the first object layer is visibly different in composition from the second object layer.