Tumbled, Polished, Vibrated Broken Tempered Glass Pieces

Abstract

Smooth, heat-treated glass fragments are created by placing a plurality of heat-treated glass fragments into a tumbling or vibrating apparatus. Each heat-treated glass fragment is formed from glass that has been heated to a temperature of at least 1000° Fahrenheit and rapidly cooled to a temperature below 800° Fahrenheit. The plurality of glass fragments is then tumbled or vibrated for a predetermined period of time such that surfaces of the heat-treated glass fragments are smoother than prior to tumbling. The glass fragments are thereafter removed from the tumbling apparatus, resulting in smoothed, heat-treated glass fragments that have a slightly rounded, bead like-shape and are suitable for direct handling without hand protection. The glass fragments as are able to be provide radiant heat in the temperature range of 400° to 800° Fahrenheit. This temperature range and the use of the heat-treated glass fragments provides for a clean burning fire that virtually eliminates any soot and carbon monoxide while burning.

Claims

1. A once heat-treated standard tempered glass fragment suited for insertion onto a gas fired burner in an enclosure, the once heat-treated standard tempered glass fragment comprising: a plurality of once heat-treated standard tempered glass fragments suitable to cover a gas burner having a plurality of gas emitting holes defined in the gas fired burner; each member of the plurality of once heat-treated standard tempered glass fragments having a random shape of non-cubical polygonal regular and irregular shaped fragments with a sharp edge, a sharp corner and a sharp burr; each member of the plurality of once heat-treated standard tempered glass fragments is made from broken once heat-treated standard tempered glass plates made from glass sheets that are made from a modified “soda-lime” and having been heat-treated once, creating a once heat-treated standard tempered glass sheet thereby, the once heat-treated standard tempered glass sheet has a surface compression of at least 3,500 and up to 10,000 pounds-force per square inch (psi); the plurality of once heat-treated standard tempered glass fragments being processed to force each member to rub against an adjacent member so as to slightly round each of the sharp edges, the sharp corners, and the sharp burrs; and wherein an unshielded human hand can safely hold a group of once heat-treated standard tempered glass fragments selected from the plurality of slightly rounded once heat-treated standard tempered glass fragments without bleeding or damage to a skin surface of the hand.

2. The once heat-treated standard tempered glass fragments of claim 1, wherein the process further comprises tumbling.

3. The once heat-treated standard tempered glass fragments of claim 1, wherein the process further comprises vibrating.

4. The once heat-treated standard tempered glass fragments of claim 1, wherein each member of the plurality of once heat-treated standard tempered glass fragments has a substantially rounded bead-like shape.

5. The once heat-treated standard tempered glass fragments of claim 1, wherein each member of the plurality of once heat-treated standard tempered glass fragments has a bean-like shape.

6. The once heat-treated standard tempered glass fragments of claim 1, wherein the plurality of once heat-treated standard tempered glass fragments is colored.

7. The once heat-treated standard tempered glass fragments of claim 1, wherein the plurality of once heat-treated standard tempered glass fragments does not have fines located therein.

8. The once heat-treated standard tempered glass fragments of claim 1, wherein the process further comprises an aqueous solution.

9. A fireplace with a gas burner that is producing a gas fire, an improvement comprising: a layer of broken non-cubical once heat-treated standard tempered glass fragments surrounding the gas fire; the layer of non-cubical once heat-treated standard tempered glass fragments being made from broken once heat-treated standard tempered glass plates that have a surface compression of at least 3,500 and up to 10,000 pounds-force per square inch (psi); the layer of broken non-cubical once heat-treated standard tempered glass fragments having a unique fracture pattern of non-cubical polygonal and irregular shaped fragments dependent upon the heat-treat temperature and quench of a glass sheet being made from a modified “soda-lime” composition, and having been heat-treated once creating a once heat-treated standard tempered glass sheet thereby, then breaking the once heat-treated standard tempered glass plates; the layer of broken non-cubical once heat-treated standard tempered glass fragments formed from non-cubical once heat-treated standard tempered glass fragments having non-cubical polygonal regular and irregular shaped fragments sharp edges, sharp corners, and sharp burrs; the layer of broken non-cubical once heat-treated standard tempered glass fragments having non-cubical polygonal regular and irregular shaped fragments and also having sharp edges, corners, and burrs the fragments then being processed to having slightly rounded sharp edges, slightly rounded sharp corners, and slightly rounded sharp burrs making the broken processed non-cubical once heat-treated standard tempered glass fragments safe to handle by a human hand without hand protection; wherein the processing of the broken non-cubical once heat-treated standard tempered glass fragments causes the broken non-cubical once heat-treated standard tempered glass to impact each other, smoothing the sharp edges, the sharp corners, and the sharp burrs of the non-cubical once heat-treated standard tempered glass fragments, resulting in broken non-cubical once heat-treated standard tempered glass fragments that are safe to handle without causing injury to the human hand, wherein a majority of small glass fines have been removed from the broken non-cubical once heat-treated standard tempered glass fragments; and wherein the non-cubical once heat-treated standard tempered glass fragments do not distort, explode, or otherwise be damaged by the gas fire; and wherein the non-cubical once heat-treated standard tempered glass fragments provide a clean burning gas fire and radiate heat in a temperature range from 400° to 800° Fahrenheit providing increased efficiency and does not block the radiant heat of the non-cubical one heat-treated standard tempered glass fragments generated by the gas fire heating the once heat-treated standard tempered glass fragments, and also provides a clean burning soot free fire that does not produce carbon-monoxide.

10. The fireplace with a gas burner that is producing a gas fire of claim 9, wherein the process further comprises tumbling.

11. The fireplace with a gas burner that is producing a gas fire of claim 9, wherein the process further comprises vibrating.

12. The fireplace with a gas burner that is producing a gas fire of claim 9, wherein each member of the plurality of once heat-treated standard tempered glass fragments has a substantially rounded bead-like shape.

13. The fireplace with a gas burner that is producing a gas fire of claim 9, wherein each member of the plurality of once heat-treated standard tempered glass fragments has a bean-like shape.

14. The fireplace with a gas burner that is producing a gas fire of claim 9, wherein the plurality of once heat-treated standard tempered glass fragments is colored.

15. A fire pit with a gas burner, an improvement comprising: a layer of broken non-cubical once heat-treated standard tempered glass fragments surrounding a flame from the gas burner; the layer of non-cubical once heat-treated standard tempered glass fragments being made from broken once heat-treated standard tempered glass plates that have a surface compression of at least 3,500 and up to 10,000 pounds-force per square inch (psi); the layer of broken non-cubical once heat-treated standard tempered glass fragments having a unique fracture pattern dependent upon the heat-treat temperature and quench then breaking the once heat-treated standard tempered glass plates; the layer of broken non-cubical once heat-treated standard tempered glass fragments formed from non-cubical once heat-treated standard tempered glass fragments having sharp edges, sharp corners, and sharp burrs; the layer of broken non-cubical once heat-treated standard tempered glass fragments having sharp edges, sharp corners, and sharp burrs being processed to having slightly rounded sharp edges, slightly rounded sharp corners, and slightly rounded sharp burrs making the broken processed non-cubical once heat-treated standard tempered glass fragments safe to handle by a human hand without hand protection; wherein the processing of the broken non-cubical once heat-treated standard tempered glass fragments causes the broken non-cubical once heat-treated standard tempered glass to impact each other, smoothing the sharp edges, the sharp corners, and the sharp burrs of the non-cubical once heat-treated standard tempered glass fragments, resulting in broken non-cubical once heat-treated standard tempered glass fragments that are safe to handle without causing injury to the human hand, wherein a majority of small glass fines have been removed from the broken non-cubical once heat-treated standard tempered glass fragments; and wherein the non-cubical once heat-treated standard tempered glass fragments do not distort, explode, or otherwise be damaged by the gas fire; and wherein the non-cubical once heat-treated standard tempered glass fragments provide a clean burning gas fire and radiate heat in a temperature range from 400° to 800° Fahrenheit providing increased efficiency and does not block the radiant heat of the non-cubical one heat-treated standard tempered glass fragments generated by the gas fire heating the once heat-treated standard tempered glass fragments, and also provides a clean burning soot free fire that does not produce carbon-monoxide (CO).

16. The fire pit with a gas burner of claim 15, wherein the process further comprises tumbling.

17. The fire pit with a gas burner of claim 15, wherein the process further comprises vibrating.

18. The fire pit with a gas burner of claim 15, wherein each member of the plurality of glass fragments has a substantially rounded bead-like shape.

19. The fire pit with a gas burner of claim 15, wherein each member of the plurality of glass fragments has a bean-like shape.

20. The fire pit with a gas burner of claim 15, wherein the plurality of glass fragments is colored.

21. A plurality of once heat-treated standard tempered glass fragments suited for insertion into an enclosure that has a gas fired burner, each of the plurality of once heat-treated standard glass fragment comprising: a glass sheet being made from a modified “soda-lime” composition and having been heat-treated once creating a once heat-treated standard tempered glass sheet thereby; the once heat-treated standard tempered glass sheet having a surface compression of at least 3,500 and up to 10,000 pounds-force per square inch (psi); a plurality of glass fragments being made from broken once heat-treated standard tempered glass sheets creating non-cubical polygonal regular and irregular shaped fragments, each fragment from the broken once heat-treated standard tempered glass sheets having sharp edges, sharp corners, and sharp burrs after breaking and being unsuitable for direct handling without protection; forcing the plurality of once heat-treated standard tempered glass fragments together creating fragments that have substantially rounded bead-like and bean-like shapes suitable for handling without protection; placing the plurality of once heat-treated standard tempered glass fragments with a substantially rounded bean-like and a substantially rounded bead-like shape around a gas fired burner and allowing the fragments to be heated by a gas fire to 400° to 800° Fahrenheit creating a clean burning, soot free fire; and the clean burning, soot free fire causing the once heat-treated standard glass fragments to radiate heat at a temperature of at least 400° to 800° Fahrenheit producing no carbon monoxide (CO) thereby.

22. The plurality of once heat-treated standard tempered glass fragments of claim 21, wherein the plurality of once heat-treated standard tempered glass fragments is colored.

23. The plurality of once heat-treated standard tempered glass fragments of claim 21, wherein the plurality of once heat-treated standard tempered glass fragments is used in a fireplace.

24. The plurality of once heat-treated standard tempered glass fragments of claim 21, wherein the plurality of once heat-treated standard tempered glass fragments is used in a fire pit.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The invention, together with further advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying drawings in which:

[0013] FIG. 1 is a flowchart showing a method for creating useful, smooth glass pieces from normal heat-treated glass, in accordance with an embodiment of the present invention;

[0014] FIG. 2 is an illustration showing exemplary broken glass shards from non-tempered glass;

[0015] FIG. 3A is an illustration showing exemplary broken heat-treated glass, in accordance with an embodiment of the present invention;

[0016] FIG. 3B is an illustration showing a magnified view of exemplary broken heat-treated glass fragments, in accordance with an embodiment of the present invention;

[0017] FIG. 4 is a flowchart showing a process for producing smooth glass fragments suitable for direct handling from heat-treated glass fragments, in accordance with an embodiment of the present invention;

[0018] FIG. 5A is an illustration showing an exemplary tumbling apparatus;

[0019] FIG. 5B is an illustration showing an exemplary horizontal tumbling apparatus;

[0020] FIG. 6 is an illustration showing an exemplary smoothed, heat-treated glass fragment after being processed according to the embodiments of the present invention.

[0021] FIG. 7 is a flowchart showing a process for producing smooth glass fragments suitable for direct handling from heat-treated glass fragments utilizing a vibratory apparatus, in accordance with an embodiment of the present invention;

[0022] FIG. 8 is an illustration showing an exemplary vibratory apparatus;

[0023] FIG. 9 is an illustration showing an exemplary use of the smoothed heat-treated glass pieces in a fire pit, in accordance with an embodiment of the present invention; and

[0024] FIG. 10 is an illustration showing an exemplary use of the smoothed heat-treated glass pieces in a fireplace, in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0025] An invention is disclosed for generating useful, smooth glass pieces from standard fully tempered glass or heat-strengthened glass, that are useful in, for example, fireplaces, fire pits, lapidary construction, art, and functional interior and exterior decorating. Embodiments of the present invention do not require specially-formulated glass or nonstandard tempering processes. The present invention methods provide a cost-effective means for in creating the smoothed glass pieces.

[0026] For the purposes of this specification, the terms polygonal shape is defined as a three (3) dimensional polygon having multiple edges of regular and irregular shapes, also known as a polygonal solid. The term irregular shapes consist of a three (3) dimensional solid that has curved edges, as well as a mixture of curved and polygonal edges.

[0027] In addition, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced without some or all of these specific details. In other instances, well known process steps have not been described in detail in order not to unnecessarily obscure the present invention.

[0028] The standard tempered glass is generally called “soda-lime” has the following chemical composition by weight:

TABLE-US-00001 Oxides Wt (%) SiO.sub.2 72.2 Na.sub.2O 15.0 CaO 6.7 MgO 4.0 Al.sub.2O.sub.3 1.2 Balance 0.2

[0029] It is not uncommon for glass manufacturers to modify the percentage by weight to create a glass that is more specific to their unique requirements. It is for this reason that the formula given is for representative purposes only. The glass would then be considered a “modified soda lime” formulation.

[0030] FIG. 1 is a flowchart showing a method 100 for creating useful, smooth glass pieces from a heat-treated glass sheet, in accordance with an embodiment of the present invention. In an initial operation 102, preprocess operations are performed. Preprocess operations can include, for example, creating a glass sheet, coloring the glass sheet, and other preprocess operations that will be apparent to those skilled in the art after a careful reading of the present disclosure. The glass sheet can be comprised of a molten silica-based mix.

[0031] In operation 104, the glass sheet is heated to at least 1000° Fahrenheit. Typically, the glass sheet is heated to approximately 1,200° F. to 1,600° F. This high temperature is substantially at or above the glass's softening point. In one embodiment, a tempering furnace can be used to heat the glass sheet. The tempering furnace may be of a continuous roller-type, fixtured roller-type, or gas-type. A gas-type tempering furnace has a plurality of blocks disposed beneath a plurality of radiant heaters. Typically, a glass sheet is placed inside the tempering furnace where the glass sheet is heated by conventional radiation, convection, and conduction heat. The glass sheet is moved along the blocks, or rollers, at a predetermined rate, which depends upon the thermal conductivity of the glass sheet.

[0032] In operation 106, an air quench is applied to the glass sheet to rapidly extract heat uniformly from both surfaces of the glass sheet, thus generating a heat-treated or tempered glass sheet. The air quench typically is applied by an air stream system. The air stream system can comprise arrays of fixed, reciprocating, or rotating nozzles. Heat is extracted uniformly from both surfaces of the glass sheet, and the quench is sustained long enough to prevent reheating of the glass surfaces from the still-hot center of the glass sheet. Uneven heat extraction may produce bow or warp. The quenched condition becomes stable when the glass sheet is reduced to a temperature of approximately 400° Fahrenheit to 600° Fahrenheit.

[0033] The immediate and sustained application of the air quench leaves the center of the glass sheet relatively hot compared to the surfaces. As the center area cools, it forces the surfaces and edges into a compressed state. As a result, a surface compression of at least 3,500 PSI to about 10,000 PSI is created.

[0034] The heat-treated glass sheet is then broken to produce heat-treated or standard fully tempered glass fragments, in operation 108. The heat-treated glass has a unique fracture pattern, which causes the glass to break into small polygonal and irregular shaped fragments having jagged edges and sharp corners. Glass that is not heat-treated as described above generally breaks into large sharp shards as illustrated in FIG. 2. FIG. 2 is an illustration showing exemplary broken glass shards 200 from non-tempered glass. As illustrated in FIG. 2, each glass shard 202a and 202b generally is relatively large and includes very sharp edges 204 and sharp burs 206.

[0035] FIG. 3A is an illustration showing exemplary sheet of standard tempered glass plate broken per the method shown in FIG. 1 heat-treated glass 302, in accordance with an embodiment of the present invention. As illustrated in FIG. 3A, a broken sheet of heat-treated glass 302 exhibits a unique fracture pattern 304, which causes the glass to break into small heat-treated polygonal and irregular shaped glass fragments 306 having jagged edges, sharp edges, sharp burrs and sharp corners. FIG. 3B is an illustration showing a magnified view of exemplary broken heat-treated glass fragments 306, in accordance with an embodiment of the present invention. Unlike the glass shards of FIG. 2, each heat-treated polygonal and irregular shaped glass fragment 306 is small and relatively uniform in size. In addition, each heat-treated polygonal and irregular shaped glass fragment 306 includes sharp edges 308 that make the heat-treated glass fragments generally unsuitable for direct handling without some form of hand protection. The once heat-treated standard tempered broken glass sheets create polygonal and irregular shaped fragments of standard once tempered glass, or heat-treated glass.

[0036] Referring back to FIG. 1, the heat-treated glass fragments are processed to produce smooth glass fragments suitable for direct handling, in operation 110. As will be discussed in greater detail subsequently, embodiments of the present invention process the heat-treated glass fragments via tumbling and/or polishing and/or vibrating. It should be noted that the term heat-treated glass shall refer to any glass that is processed to create a surface compression such that the fracture pattern of the broken glass results in many small non-cubical glass fragments. Hence, the term heat-treated glass shall refer to, for example, once heat-treated standard fully tempered glass, heat-strengthened glass, also known as toughened glass, or any other glass heat processed to create a similar fracture pattern. Post process operations are performed in operation 112. Post process operations can include, for example, using the smoothed glass pieces in fireplaces, fire pits, art, decoration, facade, stone work, lapidary, construction, paving, laminates, decorative, functional and nonfunctional interior and exterior decorating.

[0037] FIG. 4 is a flowchart showing a process 110a for producing smooth glass fragments suitable for direct handling from once heat-treated glass fragments, in accordance with an embodiment of the present invention. In an initial operation 400, pre-process operations are performed. Pre-process operations can include, for example, heating and rapidly cooling a glass sheet, obtaining tempered or heat-strengthened glass, breaking the glass so as to form broken heat-treated polygonal and irregular shaped glass fragments, and other preprocess operations that will be apparent to those skilled in the art after a careful reading of the present disclosure.

[0038] In operation 402, the heat-treated polygonal and irregular shaped glass fragments are positioned in a tumbling apparatus. Although any tumbling apparatus capable of tumbling the heat-treated glass fragments over time can be utilized with the embodiments of the present invention, FIGS. 5A and 5B are exemplary illustrations showing exemplary tumbling apparatuses for use in processing broken heat-treated glass fragments.

[0039] In particular, FIG. 5A is an illustration showing an exemplary tumbling apparatus 500, in accordance with an embodiment of the present invention. The exemplary tumbling apparatus 500 includes a base frame 502, tumbling drum 504, and a motor 506 attached to both the base frame 502 and tumbling drum 504 for drum 504 rotation. In one embodiment, the rotation drum 504 can comprise a ferrous or non-ferrous container, steel, plastic, copper, or stainless steel. The motor 506 operates to rotate the tumbling drum 504 during glass processing, as will be described in greater detail below. After obtaining the broken heat-treated glass fragments, as described above, the heat-treated glass fragments are placed within the tumbling drum 504. The tumbling drum 504 can be positioned as indicated by the tilt arrows 508 in FIG. 5A. As a result, the tumbling drum 504 can be positioned such that the glass will be tumbled horizontally, vertically, or at any angle between 0° and 90°. The tumbling of the heat-treated glass fragments will produce fines during the smoothing process that will be removed from the final product.

[0040] FIG. 5B is an illustration showing an exemplary horizontal tumbling apparatus 550. The horizontal tumbling apparatus 550 includes a lateral tumbling drum 552, a base frame 554, and a pulley-based motor 556. The pulley-based motor 556 is attached to the base frame 554 and is further in communication with the lateral tumbling drum 552 via a drive belt. As above, the pulley-based motor 556 operates to rotate the tumbling drum 554 during glass processing. Similar to above, when utilizing the horizontal tumbling apparatus 550 of FIG. 5B, the heat-treated glass fragments are placed within the lateral mixing drum 552 during operation 402.

[0041] Embodiments of the present invention can process the broken heat-treated glass fragments either aqueously or non-aqueously. Hence, in operation 404, a decision is made as to whether the once heat-treated glass fragments will be processed aqueously. If aqueous processing will be performed, the process 110a branches to operation 406. Otherwise, the process 110a branches to operation 408.

[0042] As stated above, when aqueous processing will be performed, the process 110a branches to operation 406 where optional aqueous additives are introduced to the tumbling apparatus. Referring to FIG. 5A, when utilizing aqueous processing an aqueous compound is poured into the tumbling drum 504. The aqueous compound then operates to surround the previously inserted heat-treated glass fragments and assists in smoothing during the tumbling process. Optionally, additives can be added to the aqueous compound to achieve various smoothing effects. For example, serum oxide can be mixed with water to aqueously process the heat-treated glass pieces. In addition, silicon carbide, tin oxide, and aluminum oxide are further exemplary additives that can be added to the aqueous compound.

[0043] Referring back to FIG. 4, when non-aqueous processing will be performed, the process 110a branches to operation 408 where optional non-aqueous additives are introduced to the tumbling apparatus. Referring to FIG. 5A, when utilizing non-aqueous processing optional non-aqueous additives can be inserted into the tumbling drum 504 along with the heat-treated glass fragments to achieve various smoothing effects. For example, silica sand can be placed in the tumbling drum 504 to assist in processing the heat-treated glass pieces. In addition, silicon carbide, tin oxide, and aluminum oxide are further exemplary additives that can be inserted into the tumbling drum 504.

[0044] After adding any optional additives to the tumbling apparatus in operation 406, during aqueous processing, or operation 408, during non-aqueous processing, the tumbling process is commenced to smoothen the once heat-treated standard tempered glass fragments. Turning to FIG. 5A, the tumbling drum 504 is rotated to tumble the heat-treated glass fragments along with any additives. During tumbling, the relative motion between the heat-treated polygonal and irregular shaped glass fragments and the treating elements, i.e., the aqueous compound and optional additives or non-aqueous additives, and against each other alter the surface of the heat-treated glass fragments. Hence, the relative motion polishes, de-burs, and smoothens the once heat-treated standard tempered glass fragments so as to become suitable for handling.

[0045] When an aqueous tumbling process is utilized, as described in operation 406, the heat-treated glass fragments can achieve a high degree of polished texture. Alternatively, a rougher texture can be achieved utilizing a non-aqueous tumbling process, as described in operation 408. Embodiments of the present invention typically tumble the once heat-treated standard tempered glass for a time period in the range of about 15 minutes to 2 hours, depending on the polishing effect desired. For example, shorter tumble times result in smooth bead-like heat-treated glass fragments that are less polished than result when using longer tumble times. In addition, longer tumble times generally result in more rounding of the heat-treated glass fragments than result using shorter tumble times. For example, tumbling the heat-treated glass fragments for 2 hours typically results in smooth, very rounded, bean-like or bead-like heat-treated glass fragments, or substantially rounded bead-like or bean-like shapes.

[0046] In operation 412, the smoothed, bead-like or bead-like heat-treated glass fragments are removed from the tumbling apparatus. As stated previously, the resulting smoothed, bead-like or bean-like heat-treated glass fragments are suitable for direct handling due to the removal of the sharp corners, sharp edges, and burrs. FIG. 6 is an illustration showing an exemplary smoothed, bead-like or bean-like heat-treated glass fragment 600 after being removed from the tumbling apparatus in operation 412. As illustrated in FIG. 6, the surface 602 of the bead-like or bean-like heat-treated glass fragment 600 is smooth, having smoothed edges 604 free of sharp burrs. As a result, the smoothed, bead-like or bean-like heat-treated glass fragment 600 can be directly handled without hand protection and utilized in various projects including art, decoration, facade, stone work, lapidary, construction, paving, laminates, decorative, functional and nonfunctional interior and exterior decorating.

[0047] Post process operations are performed in operation 414. Post process operations can include, for example, drying the smoothed, bead-like or bean-like heat-treated glass fragments during an aqueous tumbling process, cleaning additive material from the smoothed, bead-like or bean-like heat-treated glass fragments, and other post process operations that will be apparent to those skilled in the art after a careful reading of the present disclosure. In addition to smoothing the broken heat-treated glass pieces via tumbling, an embodiment of the present invention can produce smooth bead-like or bean-like heat-treated glass fragments via vibration, as described next with reference to FIG. 7.

[0048] FIG. 7 is a flowchart showing a process 110b for producing smooth glass fragments suitable for direct handling from heat-treated glass fragments utilizing a vibratory apparatus, in accordance with an embodiment of the present invention. In an initial operation 700, preprocess operations are performed. Preprocess operations can include, for example, heating and rapidly cooling a glass sheet, obtaining tempered or heat-strengthened glass, breaking the glass so as to form broken heat-treated glass fragments, and other preprocess operations that will be apparent to those skilled in the art after a careful reading of the present disclosure.

[0049] In operation 702, the heat-treated polygonal and irregular shaped glass fragments are positioned in a vibratory apparatus. Although any vibratory apparatus capable of tumbling the heat-treated glass fragments over time can be utilized with the embodiments of the present invention, FIG. 8 is an exemplary illustration showing an example vibratory apparatus for use in processing broken heat-treated glass fragments.

[0050] In particular, FIG. 8 is an illustration showing an exemplary vibratory apparatus 800. The exemplary vibratory apparatus 800 includes a base frame 802, vibratory drum 804, and a vibratory motor 806 attached to both the base frame 802 and vibratory drum 804 for drum 804 vibration. In one embodiment, the vibratory drum 804 can comprise a ferrous or non-ferrous container, plastic, copper, or stainless steel. The motor 806 operates to vibrate the vibratory drum 804 at a high frequency during glass processing, as will be described in greater detail below. After obtaining the broken heat-treated glass fragments, as described above, the heat-treated glass fragments are placed within the vibratory drum 804. Similar to tumbling, the vibratory drum 804 can be positioned such that the glass will be tumbled horizontal, vertically, or at any angle between 0° and 90°.

[0051] As mentioned previously, embodiments of the present invention can process the broken heat-treated polygonal and irregular shaped glass fragments either aqueously or non-aqueously. Hence, in operation 704, a decision is made as to whether the heat-treated glass fragments will be processed aqueously. If aqueous processing will be performed, the process 110b branches to operation 706. Otherwise, the process 110b branches to operation 708.

[0052] As stated above, when aqueous processing is performed, the process 110b branches to operation 706 where optional aqueous additives are introduced to the vibratory apparatus. Referring to FIG. 8, during aqueous processing an aqueous compound is poured into the vibratory drum 804. The aqueous compound then operates to surround the previously inserted heat-treated glass fragments and assists in smoothing during the vibration process. Optionally, additives can be added to the aqueous compound to achieve various smoothing effects. For example, serum oxide can be mixed with water to aqueously process the heat-treated glass pieces.

[0053] Referring back to FIG. 7, when non-aqueous processing will be performed, the process 110b branches to operation 708, where optional non-aqueous additives are introduced to the tumbling apparatus. Referring to FIG. 8, when utilizing non-aqueous processing, optional non-aqueous additives can be inserted into the vibratory drum 804 along with the heat-treated glass fragments to achieve various smoothing effects. For example, silica sand placed in the vibratory drum 804 could assist in processing the heat-treated glass pieces.

[0054] After adding any optional additives to the vibratory apparatus in operation 706, during aqueous processing, or operation 708, during non-aqueous processing, the vibration process is commenced in operation 710 to smooth the heat-treated polygonal and irregular shaped glass fragments. Turning to FIG. 8, the vibratory drum 804 is vibrated at a high frequency to vibrate the heat-treated glass fragments along with any additives. The vibration of the heat-treated glass fragments and the treating elements, i.e., the aqueous compound and optional additives or non-aqueous additives, alter the surface of the heat-treated glass fragments. As a result, the vibratory motion polishes, de-burs, and smoothens the sharp heat-treated polygonal and irregular shaped glass fragments into heat-treated fragments that have a bead-like or bean-like polygonal and irregular shape so as to become suitable for direct human handling.

[0055] When an aqueous vibratory process is utilized, as described in operation 706, the heat-treated glass fragments can achieve a high degree of polished texture. Alternatively, a rougher texture can be achieved utilizing a non-aqueous vibratory process, as described in operation 708. Embodiments of the present invention typically vibrate the heat-treated glass fragments for a time period in the range of about 15 minutes to 2 hours, depending on the polishing effect desired. For example, shorter vibration times result in smoothed heat-treated glass fragments that are less polished than result when using longer vibration times. In addition, longer vibration times generally result in more rounding of the heat-treated glass fragments than result using shorter vibration times. For example, vibrating the sharp heat-treated glass fragments for 2 hours can typically result in smooth, very rounded, bean-like or bead-like heat-treated polygonal and irregular shaped glass fragments, or substantially rounded bead-like, or bean like shaped once heat-treated standard tempered polygonal and irregular shaped glass fragments.

[0056] In operation 712, the smoothed, bead-like or bean-like heat-treated glass fragments are removed from the vibratory apparatus. As stated previously, the resulting smoothed, bead-like or bean-like heat-treated glass fragments are suitable for direct handling and can be utilized in various projects including in art, decoration, facade, stone work, lapidary, construction, paving, laminates, decorative, functional and nonfunctional interior and exterior decorating.

[0057] Post process operations are performed in operation 714. Post process operations can include, for example, drying the smoothed, bead-like or bean-like heat-treated glass fragments during an aqueous process, cleaning additive material from the smoothed, bead-like or bean-like heat-treated glass fragments, and other post process operations that will be apparent to those skilled in the art after a careful reading of the present disclosure.

[0058] As mentioned above, the smoothed, bead-like or bean-like heat-treated polygonal and irregular shaped glass pieces can be utilized in a variety of projects. In addition, because the smoothed glass pieces have been heat-treated, they can be utilized in heat related building and art projects, such as fire pits and fireplaces. FIG. 9 is an illustration showing an exemplary use of the smoothed bead-like or bean-like heat-treated glass pieces in a fire pit 900, in accordance with an embodiment of the present invention. The fire pit 900 includes a gas fire 902 formed on a plurality of smoothed, bead-like or bean-like heat-treated glass fragments 904. Typically, the smoothed, bead-like or bean-like heat-treated glass fragments 904 can be formed around a gas line situated within the fire pit 900.

[0059] Normal, non-heat-treated glass subjected to the heat of the gas fire 902 will distort, explode, melt, or otherwise be damaged from the heat. However, because the smoothed bead-like or bean-like polygonal and irregular shaped glass pieces 904 of the embodiments of the present invention have been heat-treated, for example once heat treated standard fully tempered or toughened glass, the smoothed, bead-like or bean-like heat-treated polygonal and irregular shaped glass pieces 904 will not distort, explode, or otherwise be damaged by the gas fire 902. This allows for a clean burning gas fire 902. The gas fire in the fireplace can have a temperature range of 400° to 700° Fahrenheit. This temperature range for the burning natural gas or propane assures that it is clean burning, or soot free. This temperature range also eliminates any carbon monoxide from the exhaust making it safer than other burning products. In addition, the smoothed, bead-like or bean-like heat-treated polygonal and irregular shaped glass fragments 904 radiate heat and allow increased efficiency because nothing blocks the radiant heat from the gas fire 902 and the heated glass fragments 904.

[0060] FIG. 10 is an illustration showing an exemplary use of the smoothed bead-like or bean-like once heat-treated standard tempered glass pieces in a fireplace 1000, in accordance with an embodiment of the present invention. Similar to the fire pit of FIG. 9, the fireplace 1000 of FIG. 10 includes a gas fire 902 formed on a plurality of smoothed, bead-like or bean-like heat-treated glass fragments 904. Typically, the smoothed, bead-like or bean-like heat-treated polygonal and irregular shaped glass fragments 904 can be formed around gas line situated within the fireplace 1000. As mentioned above, the smoothed, bead-like heat-treated glass pieces 904 will not distort, explode, or otherwise be damaged by the gas fire 902 because the smoothed bead-like or bean-like glass pieces 904 of the embodiments of the present invention have been heat-treated. Since the temperature range for the fireplace is 400° to 700° Fahrenheit, this allows for a very clean burning gas fire 902 that is soot and carbon monoxide free. In addition, the smoothed, bead-like or bean-like heat-treated polygonal shaped glass fragments 904 radiate heat and allow increased efficiency because nothing blocks the radiant heat from the gas fire 902 and the heated polygonal and irregular shaped glass fragments 904.

[0061] Although the foregoing invention has been described in some detail for purposes of clarity of understanding, it will be apparent that certain changes and modifications may be practiced within the scope of the invention. Accordingly, the present embodiments are to be considered as illustrative and not restrictive, and the invention is not to be limited to the details given herein, but may be modified within scope and equivalents of the invention.