Method of producing a decorative glass panel

Abstract

A decorative glass panel, and a method of production thereof, is provided for a door or window, and comprises a flat glass panel having an outer surface, an inner surface, and a thickness. Using a computer controlled router, a prescribed pattern is formed in at least the outer surface of the flat glass panel, the prescribed pattern including at least one substantially V-shaped groove. The pattern is transferred to a resin plotter that applies an air-curable resin within each substantially V-shaped groove according to a prescribed tip speed, pumping speed and resin viscosity. Thereafter, the resin is cured.

We claim: 
     
         1 . A method of forming a decorative glass panel with a pattern of V-shaped grooves, comprising:
 (a) utilizing a computer-controlled router to form a prescribed pattern in at least one of an outer and inner surface of a flat glass panel, the prescribed pattern comprising at least one substantially V-shaped groove, each groove having a width of between 9.0 mm and 19.5 mm and a depth of between 0.5 mm and 1.5 mm;   (b) translating and transferring the prescribed pattern to a resin plotter program;   (c) applying an air-curable resin bead in the at least one substantially V-shaped groove with a computer-driven plotter forming the prescribed pattern, utilizing a tip speed of between 280 and 320 mm per minute, a pumping speed between 60 and 80 ml per minute, a tip height above the bottom of the groove of between 1.5 and 5.0 mm, and a resin viscosity between 11,000 and 16,000 centipoise when measured at an ambient room temperature of about 72 degrees Fahrenheit; and   (c) curing the air-curable resin.   
     
     
         2 . The method of  claim 1 , wherein the at least one substantially V-shaped groove is formed with a diamond-cutting wheel. 
     
     
         3 . The method of  claim 1 , further comprising a step of polishing the at least one substantially V-shaped groove with a softer wheel before applying the air-curable resin. 
     
     
         4 . The method of  claim 3  wherein the softer wheel is a red clay wheel. 
     
     
         5 . The method of  claim 4  wherein the polishing step polishes the at least one substantially V-shaped groove to a clear finish. 
     
     
         6 . The method of  claim 1 , wherein the V-shaped groove has a width of about 14 mm. 
     
     
         7 . The method of  claim 1 , wherein the V-shaped groove has a depth of about 1 mm. 
     
     
         8 . The method of  claim 1 , wherein the air-curable resin is a continuous bead in the at least one substantially V-shaped groove and has a width within the groove of between about 4.5 mm and 5.5 mm. 
     
     
         9 . The method of  claim 8 , wherein the width of the air-curable resin bead applied in the at least one substantially V-shaped groove has a width of about 5 mm. 
     
     
         10 . The method of  claim 1 , wherein the air-curable resin comprises a resin hardener. 
     
     
         11 . The method of  claim 1 , wherein the air-curable resin is applied with an X-Y plotter. 
     
     
         12 . The method of  claim 11 , wherein the X-Y plotter is programmed to apply the air-curable resin across intersecting V-shaped grooves such that intersecting beads of resin are applied before the air-cured resin cures, thereby forming an even resin bead depth.